Still in Painting Stages.....
While I was looking at FourBanger on day, I decided that I didn't want
to repair the little bit of rust on the factory doors. So I went and
contacted HO Fibertrend to have them make me a new set of fiberglass
doors.
In this episode, I show how I mounted the new doors on a custom hinge
configuration.
Here's the problem:
Fiberglass doors don't have enough material to mount a hinge on them
without breaking the front of the door from weight.
My job was to design a plate of metal that I could weld the hinges onto
and then bolt onto the doors. Here's how I did it....
I started out by cutting elongated "D" shapes out of metal. The goal
here was to sandwich the plates between the fiberglass on the front
side of the door to add strength and for a place to weld the hinges to.
Once the plates were cut out, I drilled holes in them so I could
through-bolt the plates and clamp them together once on the door. I
welded nuts onto the back side of the inner plate so that it holds them
in place while bolting up to the door.
Once the plates were bolted to the door, I had my friend hold the door
in place while I checked all the body lines and made sure it was within
spec of the body. I then tack welded the hinges in place. After
checking to see if the door would open and close without binding, I
took the door back off and unbolted the hinge plates so I could weld
the hinges on permanently and not catch the door on fire.
Then, to permanently mount the hinge plate onto the door, I used epoxy
along with the bolts.
To do this, I needed to mix some Cab-O-Sil with the epoxy to make a
paste so it wouldn't run off the plates when I tried to assemble them
on the door. Cab-O-Sil is basically Talc Powder. It's used in
fiberglass work when a high build paste is needed.
I used this brand of Cab-O-Sil......
....And mixed in proper amounts of this cheap epoxy. I wasn't really
happy with this product. It said 30 minute drying time, but it really
took 3 weeks to fully cure. The Cab-O-Sil might have affected it some,
but I don't think they put enough hardner in to begin with.
After the two were mixed together to make a paste, I put a decent
amount on each plate's respective side and assembled them. I cranked
the bolts down and the epoxy paste oozed out of the crevices filling
the gaps. I took my finger and removed the excess from the front plate.
Here, the door is done! I used new hinge bushings from 5.0 resto.com.
Wide open and working perfectly.
The next part of the door install calls for cutting out the holes where
the latching mechanism for the striker pin is located.
I got that completed and the door opens and closes. I cut out the
original section for the inside unlatching lever and remounted it on
the door. Everything works perfectly. I am in the process of mounting
the outside door handle. I'll have pics of that soon.
These doors are far lighter than a factory door! They have provisions
molded into them for the original roll up windows. I am in the process
of trying to mold my own plexi-glass windows for it. I plan on using
the original window regulator, but intend on lightening it slightly
with "speed holes" lol.
And for the few Emails I got asking if FourBanger still runs....
OF COURSE SHE STILL RUNS!!!
And NO, I haven't sold her.
The Volvo head is on hold for a few more months until I get this paint
job done. I have a brand new TIG welder, but can't use it until my new
house is built. I'll get to it soon.
