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TinCanFab Sun Jun 27, 2010 12:53 pm

TinCanFab Sun Jun 27, 2010 12:59 pm

OK, 5 out of 6 hinge areas were torn off the engine lid and both t c doors. I've never seen anyone repair these the way I did. Ended up the best way I could imagine. It's hard to tell from the pics, so I'll explain:

When you try to eyeball the threaded areas that hold the hinges to the lids, welding it back together with the right angle is crucial, a few degrees off and the door won't fit the body right.

Look at the backside of a treasure chest door. The top reinforcement rail has the threaded plates. The lower rails have an indent that is the same as the top one. Make a template to mark the holes and drill them into the lower section. Cut it out, bolt a hinge with nuts to the donor clip. Weld the nuts on the backside when ready. Before you do that, lay the clip on the top section thats torn out and trace it like a template. Cut the torn one out and the new clip w nuts welded on the back. Make a patch for the hole you now have in the bottom rail.

TinCanFab Sun Jun 27, 2010 1:09 pm

Here is the bottom rail that normally has no holes in it

TinCanFab Sun Jun 27, 2010 1:11 pm

Here is the donor cut out and placed next to its new home, the top of the door. The clip will align itself in the original indentation making the placement dummy proof. Just dont weld it in crooked

TinCanFab Sun Jun 27, 2010 1:14 pm

Just line it up flush with all the edges and presto, in the perfect spot

TinCanFab Sun Jun 27, 2010 1:17 pm

Just make a basic patch to fill the hole at the bottom of the door. It wont look perfect unless you want to try and copy a dimpled piece to put back in. If you cut both sides out, they will match at least

66busman Sun Jun 27, 2010 1:23 pm

Great work! I love the use of recycled metal throughout.

TinCanFab Sun Jun 27, 2010 1:24 pm

Had to make this spring carrier piece that was ripped off as well

TinCanFab Sun Jun 27, 2010 1:27 pm

Treasure Chest Door:

Man, one of mine was rotted pretty bad at the bottom. The outer skin and reinforcement rail needed replacement

Beat up Chevy door to the rescue again! Keep in mind this is the first major fabbing I've done myself, and with scrap metal. All it takes is patience and common sense. If you are a rookie, you CAN do it

TinCanFab Sun Jun 27, 2010 1:33 pm

TinCanFab Sun Jun 27, 2010 1:35 pm

OK, I'm taking a flimsy piece of sheet metal and hand forming it with my hands and a bench vise and a body hammer. The trick for me was to slowly stretch the metal from the inside towards the edges. I did it in 2 stages. DON'T try and bend this in just one quick bend without a sheetmetal brake.

I used my good door as a way to measure everything. All angles and measurements

TinCanFab Sun Jun 27, 2010 1:40 pm

TinCanFab Sun Jun 27, 2010 1:45 pm

On to the outer skin now...

TinCanFab Sun Jun 27, 2010 1:49 pm

An old metal shelf I found by the dumpster at work! The biggest issue here is folding the new skin's lip over the edge to look factory

TinCanFab Sun Jun 27, 2010 1:53 pm

Hand folded lip

TinCanFab Sun Jun 27, 2010 1:53 pm

TinCanFab Sun Jun 27, 2010 2:08 pm


Here I needed Gerson's help. Funky green is awesome. All 8 pieces of inner and outer rocker were wasted

TinCanFab Sun Jun 27, 2010 2:24 pm

Made this piece, but I'm now gonna replace the whole floor. It's easier than shoving your head in that space to fab patches

TinCanFab Sun Jun 27, 2010 2:28 pm

TinCanFab Sun Jun 27, 2010 2:38 pm

Epoxy painted the insides

When I'm finished with the treasure chest, I'll do the other side. Already have the green metal

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