Sunday, June 16, 2013

door nightmare continued

We were able to work on rebuilding the first door this weekend.  The bottom panel was a bit tricky, but we did really well I think (only had to recut a new piece once!)
We were able to put the inside bend in with the new brake, but the flange end had to be bent the old-fashioned way.  With 2  pieces of plywood cut to the curve, sheet metal clamped between the plywood and sheet metal flange hammered over.  It is a very gradual curve - only 2.5'' towards the corners, but 3'' deep at the center.
The outside edge toward the bottom, we used a piece from the original doors that was near the latch to patch the rusted corner and 'terminate' the layered bend also.  It worked out really well I think!

After replacing part of the steel where the top hinge was, we realized that more needed to be replaced when Brian started welding and the original steel was just too thin, so we cut out more rotten steel.......


I forgot to get a pic of the repair on the upper hinge, but this is what the bottom looked like at the end of the day Sunday....

 The hinge dimples might be a challenge in this thick steel.....
 This pic shows the curve of the bottom a little better.......
Hopefully by next Sunday, we'll be hanging this door.  New skin from the beltline down will be done at a later date.


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