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Old 01-04-2018, 09:52 PM
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pplace pplace is offline
MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default Finishing lower door skin

Looking back I'm amazed I don't have any pictures of fabricating and shaping the exterior door skins from the windows down?!?! This was obviously a fairly involved process, and as well documented as I did the rest of the build (I obviously have many more pictures of the build than I'm able to share here. These posts are directed more towards the metal work portion of the project)

Sorry for the lack of process pics here....

I did fabricate 100% of the exterior skin below the window (previously you saw how I did the door top / window opening portion)

I created the door skin in two parts:

1. From the window down to the fender body line / fade away.
2. From the fender fade away to the bottom of the door obviously.z
These panels do look fairly "flat" except for the curve to the window and the fade away, but there certainly was crown added both vertically and horizontally to keep the correct flow of the cab in each direction and to also ensure some "strength" in the door skin itself.

The panels were shaped, then welded together and the fade away "dialed" in on the English wheel, etc. Once the skin was final shaped it was hemmed over the door shell just like I did on the top (and spot welded in multiple spots to "lock" it in.

I was very happy to end with very nice even door gaps both in "width" but also flushness to the surrounding panels....whew!

I remember feeling so proud and happy at this portion of the project. It was really coming along and starting to look like something to be proud of!

I realized I never added a picture of the project how it arrived to me. I'll add one to show how I slightly changed the "chop" or look of the roof. Previously the door window opening was very rectangle (top and bottom edges were basically parallel) In order to give a nicer look I subtly lowered the front a bit in the process of building the door jambs, doors and remaking the roof skins. The finished result gives the window opening a slight "wedge" front to back. Much better appearance to my eyes.

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Last edited by pplace; 01-04-2018 at 10:10 PM.
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