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  #741  
Old 07-01-2017, 08:06 AM
Gojeep Gojeep is offline
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Not much to show as been busy going through all the saved panels from the donors to sell what I can and scrap the rest to get some much needed room and money.


This is what was left that was not worth selling of the leftover chassis and body parts from the three donors now that the cab is finished. 360kg/800lbs to the scrap metal place. Got a whole $36!


Can see why I threw this door out as was the one that took the brunt of the Harley Davidson at 100 mph!


Still managed to save the latch, electric window and wiring from it to sell


Setting the final gaps on the door now that everything is welded in. Top is leaning out a bit but flush everywhere else.


Other side is leaning out only at the top as well.


Tried forcing the top of the door inwards but would then kick out the diagonally opposite corner out and alter the gaps already set. So just cut part of the way in with a thin disc and could pull over by hand and reweld.


Both sides are nice a flush now all the way around.


I wanted to close this gap up more across the top when I chopped the window frames, but couldn't as would loose the correct gap in the inside of the frame. All the ones I have looked at are like this from the factory.


Had no welding rod to weld to the top but by the time you weld both sides of that you might as well tack along the top in one go like this.


I flush grind/sand the sides and then fit the door back up leaving the top untouched at this stage. Ran a marker along the top and then scribed a line under some 1/8" flat to set the cut line.


Gaps the same now all the way around. Back corner look tight in this shot but not when measured.


This door the front edge closed up when it was made flush. This was fixed simply by placing a block of timber on the front edge with the door open and hitting it with a mallet. That corrected the gap at the back of the door again as well to what it was before. Some filing and re welding was also needed.


This door now done too. Shadow makes the top gap look bigger though.
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Last edited by Gojeep; 08-14-2017 at 04:56 AM.
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  #742  
Old 09-17-2017, 04:12 AM
Gojeep Gojeep is offline
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Searched for a while for replacement door handles to suit new bear claw latches which are much safer than the old 70 year old stock ones.


Needed extra clearance for the handle link inside to clear the window, so decided that raising the mounting area to the height of the ribs worked best. The new handle didn't fit between them anyway.


Made the patch clear the old hole and move it inwards at the same time.


Welded in. Moving the handle inwards means the mounting pad lines up with the end of the existing ribs and moved the link over the glass rather than on top of the glass channel for more clearance.


After hours of searching I ended up choosing some die-cast chrome handles I had spare imported for my XJ Jeep Cherokee to replace the plastic ones it had.


Used the handle's gasket to mark out the hole needed.


Holes cutout and hole drilled for the stud at the other end.


Need to build a mounting pad for this end too and do something about the centre rib.


I thought shortening the rib was the best thing as gives more clearance for the knuckles.


I had cut a slot up the middle of the rib and then hammered it down do get rid of the excess material. The slot closed right up once flat, so then just welded it closed. A new mounting pad for the handle will be added after cutting out the area in the same way as the other end.


As it was hard to planish the area flat after welding, so I made up this dolly to suit out of some scrap.


Laying the door over on a trestle, I could just hammer down on the dolly to flatten the two mounting pads.


Think the size and squareness of the handle suits the door.


The slightly bigger size suits the proportions of the bigger than stock door as well.


Can see how the rib removal behind the handle works well for the knuckle clearance.
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  #743  
Old 09-17-2017, 04:53 AM
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That looks like a factory install.
Sweet.
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  #744  
Old 09-17-2017, 08:42 AM
blue62 blue62 is offline
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your build is one I like to follow.
Had not seen you for a while.
Glad your back.
You do wonderful inventive work!
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  #745  
Old 09-17-2017, 08:50 AM
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Steve Hamilton Steve Hamilton is offline
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Very nicely adapted

Thanks for sharing

Steve
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  #746  
Old 09-17-2017, 10:43 AM
cliffrod cliffrod is offline
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Man, Marcus- nothing you do with your project fails to impress. What a great thread.
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  #747  
Old 09-17-2017, 06:44 PM
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Excellent work Marcus, can't wait to get back into mine.
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  #748  
Old 09-17-2017, 08:00 PM
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A1, as always.
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  #749  
Old 09-18-2017, 05:51 AM
Gojeep Gojeep is offline
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Many thanks for all the comments.


Quote:
Originally Posted by blue62 View Post
your build is one I like to follow.
Had not seen you for a while.
Glad your back.
You do wonderful inventive work!
Took a couple of weeks off the build just so I could change all the photos address's to a new domain and server.
Then spent the last 5.5 weeks exploring Denmark, Norway, Greenland and Iceland! Been a trip we have been wanting to do for over 10 years and it didn't disappoint.
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  #750  
Old 09-18-2017, 09:21 AM
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Default GrandWillys Project

Marcus, splendid solution for the door handles.
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