Doors.

[penguin45]

A new first. Four doors to restore, rather than a whole car. The shells are reasonably solid and Carl has supplied a full set of skins. I had hoped to get further faster with this, but I've had a stinking cold all week and it's been pretty cold as well.

DSCN4698 by Penguin 45, on Flickr

First problem - find the spot welds. Most door skins will have a spot weld somewhere each end to locate the skin. Investigation showed that the inner edge of the window surround has 16 alone!

DSCN4699 by Penguin 45, on Flickr

You can see some here. Very small, so a 6mm spot weld drill was used at a dead slow setting for accuracy.

DSCN4700 by Penguin 45, on Flickr

I quickly realised that trying to get the skins off in a salvagable condition by unfolding the crimped edge was going to prove impossible, so the flap wheel was used to cut the outer fold, followed by the cold chisel to split things apart. This revealed that there were further spot welds along the bottom edge and up the sides. Drilled them out and the skin peels away.

DSCN4701 by Penguin 45, on Flickr

Shell is pretty solid and doesn't appear to need any welded repairs. Buzz that surface rust off, treat it and paint it then the new skin can go on.

P45.

[penguin45]

Managed most of a day in the garage today. First door frame now cleaned up, de-rusted, etched and primed.

Landcrab doors by Penguin 45, on Flickr

Whilst that was drying off (It's a bit chilly up here in Yorkshire), I attacked the next one.

Landcrab doors by Penguin 45, on Flickr

This one required more work, as you can see how water has attacked the door bottom and the inner skin. It wasn't actually through and the door frame was mainly surface rust, but a few pinholes had to be zapped in with the mig.

Landcrab doors by Penguin 45, on Flickr

In the meantime, the first door had fully dried. Rather than try and weld the window surround into place, I have bonded it home using U-pol Tiger Seal. This will form a watertight seal between the inner and outer skins, whilst being amazingly strong. It is the 21^st century after all. As you can see, a few clamps were required. I'll leave that all clamped up until tomorrow.

The second door has been cleaned up, etched and primed, so whilst that is drying, I set about the third door.

Landcrab doors by Penguin 45, on Flickr

This has some more serious rust. That corner plate is going to have to be cut away and replaced, as well as a section of the bottom flange. Quite straightforward stuff really, although I have noted that each succeeding door has been worse than the previous one. What will door four be like? Hopefully I'll find out tomorrow.

P45.

[penguin45]

Managed a few hours on these today, due to being distracted by Jag welding, driving practice with No. 1 twin and repairing our old dining room table. Wood. Horrible stuff. Can't weld it. And to think people made cars out of it....

So:

Landcrab Doors by Penguin 45, on Flickr

Rust chopped out of door three.

Landcrab Doors by Penguin 45, on Flickr

And replaced. Surface rust treated, etch primed and now in primer.

Landcrab Doors by Penguin 45, on Flickr

Meantimes, door two has had the skin bonded on around the window frame. Just 36 clamps used.

All for now,

P45.

[penguin45]

Got these finished - more of the same really.

Landcrab doors by Penguin 45, on Flickr

Landcrab doors by Penguin 45, on Flickr

Saved this one 'til last as it looked the most challenging - the skin had blown through.

Landcrab doors by Penguin 45, on Flickr

Landcrab doors by Penguin 45, on Flickr

Landcrab doors by Penguin 45, on Flickr

Lot of surface rust to clean off, but the wire wheel in the angle grinder knows best.

Landcrab doors by Penguin 45, on Flickr

Landcrab doors by Penguin 45, on Flickr

So apart from zapping in a couple of pinholes, that was it. Bit of an anti-climax. However, the funds went into the Red Dog's cylinder head and then some.

P45.