Another small piece of the puzzle done this week.
Need to make the missing part of the upper frame above the door. I decided to chop the short section off at the factory join at the A pillar to put a longer single piece in.
The section I cut out shows it is made up of three pieces. The main structural part in the middle with the top gutter part brazed on where the roof is attached. The channel part is on the inside and where the tack strip for the upholstery is finished off around the door opening.
The main part now welded in place. The length of it was the last time I could adjust the door gaps to make sure it all lined up and was square.
Got both sides done so now the roof main frame size is fixed for the first time.
The top section was made next. The blank was cut with a curve on the outside to match that of the outside of the door. Made wider than needed to make folding the outside edges easier. The gutter was made to follow that curve though a step roller. The inside fold was just done in a folder, but the curved side needed to be done with my tipping wheel setup. Just a large hardened washer over part of one of the lowers in the bead roller. Can see it in the background of the shot showing the old piece in my hand. The fold was finished off by hand over the edge of the bench. The excess was trimmed off once the folding was done.
Gutter now in place.
Found use for my old wood splitter head when I was hammering out any bumps inside the gutter. Due to the angle of the windscreen, a normal dolly wouldn't fit underneath. Also used this hammer I had modified to fit inside the step of the gutter. A lot of time was also spent making sure the getter was the same height and distance from the panel all the way around as well.
Found this shot of the same cab with a roof chop done through the pillars all the way around. Notice how the windscreen to door window proportion is different to mine where I have lowered the screen without chopping it. Don't forget my cab is 9" wider and 7" longer than this cab too which would exaggerate the difference.
