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24-05-2016
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LokRinger
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Join Date: Jul 2002
Location: Victoria
Posts: 6,864
Likes: 788
Liked 1,744 Times in 551 Posts
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A little update this week. Just small stuff that needs to be done.
Because I am shortening the door opening by 60mm-2.5", I also have to move the scallop in the door sill the same amount. This scallop lines up with the door drain so water inside the door can exit.
Better man than me would have beaten the scallop out and hammered in a new one in the new position. Access to the back was limited so decided to cut it out. Left 60mm in front of it, original is the top one, and did the same on the other side. Then just swapped them left to right.
So the right side one is now welded in on this side moving the scallop forward. Thought this was quicker and less welding than cutting just the scallop out and then welding in an angle piece to fill the spot, and then cut a new hole to weld a new scallop in place!
New B pillar clamped in place to show distance is the same in front of it as before.
The end of the panel where it dog legged onto the B pillar has been cut off.
New piece to extend the body work forward onto the new B pillar tacked in.
Tig welded it together. First time welding vertical with a tig over such a long distance. Much easier than I would have thought.
Made a dolly up from a old tow hook from my Jeep to fit between the B pillar and the body so I could planish it to stretch the weld shrink out.
Getting there slowly with just some more detail work left to do.
Last edited by Gojeep; 14-08-2017 at 03:03 AM.
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24-05-2016
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Lowranger Shocker
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Join Date: Oct 2003
Location: Hobart TAS
Age: 61
Posts: 1,679 What Jeep do I drive?: CJ
Likes: 41
Liked 133 Times in 100 Posts
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neat solution with the scallop, well done
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Not another V8!
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29-05-2016
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LokRinger
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Join Date: Jul 2002
Location: Victoria
Posts: 6,864
Likes: 788
Liked 1,744 Times in 551 Posts
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Spent more hours on getting the shape of the extension bit better and smoother. Welded the second B pillar to it. Will weld that to the original B pillar and floor later in case I need to adjust it.
I made sure the the pillar matched the door back edge when square to the sill.
Knowing how much to cut off the other part of the door was just a matter of measuring the gap.
I didn't take off anything for the door gap so I had 3mm-1/8" adjustment to get good alignment. Here it sits straight after the first cut.
The extension piece is just sitting on the sill without the gap needed so why it is bit low. But can see that I will need to do something about the top opening in the panel.
It had a dimple right where I need it to be flat so raised that first. Then got a piece of scrap the right thickness to match the step around the hole. Welded that onto a thicker piece to hammer against.
Clamped it into place and supported the bottom of the vice grip and also the door skin to free up a hand.
Just hit down with a brickies bolter to set the form I needed.
Step nows extends to the end and just needs a bit of planishing and trimming.
Both sides done now.
All lines up pretty well considering these two parts of door came off the production line 10 years apart.
I think the shorter door and wider pillar looks better. So the door is 115mm-4.5" wider than stock and the B pillar 60mm-2.5" wider.
Ribs line up pretty well but there will be plenty of work to get it all sitting just right after welding.
Last edited by Gojeep; 14-08-2017 at 03:08 AM.
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29-05-2016
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MonsterMoose
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Join Date: Jun 2010
Location: Noosa QLD.
Age: 58
Posts: 7,940 What Jeep do I drive?: WK2
Likes: 1,432
Liked 809 Times in 466 Posts
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All that work on the inside of the door! Just amazed at your level of detail as usual.
Though this is worse than waiting for the next episode of Game of Thrones....
Sent from my SM-G900I using Tapatalk
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2010 JK, then a 2015 KL Trailhawk, now a 2017 GC Trailhawk!
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30-05-2016
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LokRinger
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Join Date: Jul 2002
Location: Victoria
Posts: 6,864
Likes: 788
Liked 1,744 Times in 551 Posts
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Quote:
Originally Posted by SeaComms
All that work on the inside of the door! Just amazed at your level of detail as usual.
Though this is worse than waiting for the next episode of Game of Thrones....
Sent from my SM-G900I using Tapatalk
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Yes, it all gets covered up by the door card, but you guys get to see it in the mean time.
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31-05-2016
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DetroitDemon
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Join Date: Jun 2009
Location: Casino
Posts: 4,801 What Jeep do I drive?: XJ
Likes: 5,510
Liked 1,325 Times in 717 Posts
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Quote:
Originally Posted by Gojeep
Yes, it all gets covered up by the door card, but you guys get to see it in the mean time.
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And it's appreciated, man...
That door/pillar proportion is spot on, Marcus. You can tell, even now.
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31-05-2016
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LokRinger
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Join Date: Jul 2002
Location: Victoria
Posts: 6,864
Likes: 788
Liked 1,744 Times in 551 Posts
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Quote:
Originally Posted by bruggz351
And it's appreciated, man...
That door/pillar proportion is spot on, Marcus. You can tell, even now.
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I think so too. If the window still looks a little long I will refit the 1/4 vent window. Rather leave it out if I can as quieter and cleaner looking without it.
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