Found another Chevy
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- G-Colonel
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Re: Found another Chevy
A couple of months ago I started to dabble with the door latches only to find out that the problems were a little more involved than I was ready to deal with at the time. This post is focusing on the passenger door, it is the more problematic of the 2. At first glance it doesn't look too bad, a new Escutcheon would cover everything.
upon closer inspection the door handle hole has been repaired sometime in the past and is off center. The horizontal and vertical lines represent the correct hole location.
Here's what the inside looked like...
After looking at it for a while I thought the best approach was to cut it out and start over...
Wish me luck...Kelley
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Re: Found another Chevy
I always had trouble welding thin sheet metal without buckling it, but I'm certain with your skills this will be a piece of cake. Looking forward to seeing the result.
John
John
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Re: Found another Chevy
Hi John,
Butt welding light gauge sheet metal is a bitch for me too, I'm not really set up for it. The welding machine I used has .035 solid wire, not really ideal for sheet metal. I had some Escutcheon repair washers made up to correct the wallowed out hole. I also had an alignment tool made up... I cut a chunk out of a "parts'' door that had a slight arc to match the damaged area... It's best to widdle the patch down until it fits just right... I just work my way around, not tacking it until the 2 faces are flush on the outside, It's not always pretty. Weld a little and let it cool to the touch. Grinding and sanding can take a while too. Too much heat from grinding can also distort the steel. The next step was to cut the hole for the repair washer, I used a 1-1/4'' hole saw. I used a little JB Weld to fill the grooves in the door handles... The handles are drooping because I Mis placed the springs, they'll turn up.
Butt welding light gauge sheet metal is a bitch for me too, I'm not really set up for it. The welding machine I used has .035 solid wire, not really ideal for sheet metal. I had some Escutcheon repair washers made up to correct the wallowed out hole. I also had an alignment tool made up... I cut a chunk out of a "parts'' door that had a slight arc to match the damaged area... It's best to widdle the patch down until it fits just right... I just work my way around, not tacking it until the 2 faces are flush on the outside, It's not always pretty. Weld a little and let it cool to the touch. Grinding and sanding can take a while too. Too much heat from grinding can also distort the steel. The next step was to cut the hole for the repair washer, I used a 1-1/4'' hole saw. I used a little JB Weld to fill the grooves in the door handles... The handles are drooping because I Mis placed the springs, they'll turn up.
Last edited by kelley on Sat Sep 16, 2017 11:37 pm, edited 1 time in total.
Kelley
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Re: Found another Chevy
Look at you go Jon. I swear, I am beginning to think that you could build an entirely new truck .
In Loving Memoriam: George R. Hancock. 20 Mar. 1938 - 11 Jan. 2017. U.S.A.F. 1956 - 1962. R.I.P. Dad.
In Loving Memoriam: Ann Hancock, 08 Mar. 1934 - 25 Sept. 2021. R.N. 1960 - 2005. R.I.P. Mom.
Thank You BOTH for always being there.
My YouTube Channel. https://www.youtube.com/channel/UCaMKEv ... M3g/videos.
In Loving Memoriam: Ann Hancock, 08 Mar. 1934 - 25 Sept. 2021. R.N. 1960 - 2005. R.I.P. Mom.
Thank You BOTH for always being there.
My YouTube Channel. https://www.youtube.com/channel/UCaMKEv ... M3g/videos.
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Re: Found another Chevy
Jon,
Creative fix on the door handle. I was wondering if you were going to splice in new metal. So did the grommet fit well and does the door handle function as per original? How does the alignment tool locate the hole centerline?
I need to do the same repair on the passenger side of Gert...was hoping your remedy would be a little more basic. My door has been collecting dust in the shop waiting to see your fix.
Thanks for sharing.
Paul
Creative fix on the door handle. I was wondering if you were going to splice in new metal. So did the grommet fit well and does the door handle function as per original? How does the alignment tool locate the hole centerline?
I need to do the same repair on the passenger side of Gert...was hoping your remedy would be a little more basic. My door has been collecting dust in the shop waiting to see your fix.
Thanks for sharing.
Paul
1941 G4112 Chevrolet with Hercules dump bed
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Re: Found another Chevy
Thanks Guys,
Yes the grommet fits and the door handle works great, the latches needed to be loosened up but work well now. I think a dab of grease on the door handle from time to time would be a good idea.
The alignment tool keeps the I.D. of the repair washer centered on the 1/2'' hole that's inside of the door, I should have taken a pic of it in use.
The most difficult part was replacing the outer skin. I would highly recommend using .023 solid wire in your feeder, the .035 I used worked but was a PITA.
Yes the grommet fits and the door handle works great, the latches needed to be loosened up but work well now. I think a dab of grease on the door handle from time to time would be a good idea.
The alignment tool keeps the I.D. of the repair washer centered on the 1/2'' hole that's inside of the door, I should have taken a pic of it in use.
The most difficult part was replacing the outer skin. I would highly recommend using .023 solid wire in your feeder, the .035 I used worked but was a PITA.
Kelley
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Re: Found another Chevy
Do you prime and then seal the back sides of your welds when possible ? That step was suggested to me years ago by a retired body man. He Told me of vehicles that he has seen , that after a few years looked like patch work quilts from the rust coming threw the back side . I use 3m seam seal or Sem 29372 .
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Re: Found another Chevy
Hi Cooler King,
I did shoot a little rattle can primer on the inside of the doors, admittedly a 1/2 Ass effort, I've also seen repairs rust around the perimeter where the welds are. IMO the cheapest, easiest way to keep vehicles from rusting is to spray them with oil on an annual basis. A $3 can of WD-40 once a year, sprayed in all the little nooks and crannies slows it down a lot. On a long enough time line, the truck WILL rust away.
I did shoot a little rattle can primer on the inside of the doors, admittedly a 1/2 Ass effort, I've also seen repairs rust around the perimeter where the welds are. IMO the cheapest, easiest way to keep vehicles from rusting is to spray them with oil on an annual basis. A $3 can of WD-40 once a year, sprayed in all the little nooks and crannies slows it down a lot. On a long enough time line, the truck WILL rust away.
Kelley
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Re: Found another Chevy
My eyes sure are not what they use to be. After grinding down sheet metal patches I recently started checking my work with a flashlight from the backside, sometimes see a few pin holes (porosity). They are not visible without the flashlight . Just looking threw reading glasses, or the cheater lenses in my welding helmet looks good to go.
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Re: Found another Chevy
After grinding and sanding the pin holes become visible, I had to go over each door 2-3 times to get them all. The Flashlight is a good idea, I held the door up to the light. The pin holes really show up when it comes back from the sandblaster.
I need readers for everything, have not used a magnifier in my helmet yet, probably should.
I need readers for everything, have not used a magnifier in my helmet yet, probably should.
Kelley
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Re: Found another Chevy
I try to stay away from harbor freight but they have a sand blaster gun that has a hose that you stick in a bucket of sand. Thought I would give it a shot it works. I just use it for spot blasting. rust pits, welds etc.
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Re: Found another Chevy
I'm not a big Harbor Freight guy either, but they have a store 1/2 mile from my shop. Thanks, I'll have to check it out.
Kelley
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Re: Found another Chevy
I'm not a big truck guy, really, but the skill and craftsmanship here is amazing. I do have a '37 Ford Commercial truck which will be a restoration/modification. I'm sure some of your tips will come in handy. I stole your vice pictures, I might build something similar! I have read this entire thread in 2 days...I probably should find some work to do! lol
Luke Sparks
MAJ (R), USA
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MAJ (R), USA
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- Gordon_M
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Re: Found another Chevy
Here's the cheap fix of the day ...
Over the last seventy years or so, the hard cab GMC and Chevrolet door handles have all twisted slightly, resulting in that ugly droop you pictured even if the springs and latches are OK.
The cure ? just swap the drivers and passengers handles, side to side, takes a couple of minutes.
Of course in another seventy years or so you'll have to swap them back again ...
Over the last seventy years or so, the hard cab GMC and Chevrolet door handles have all twisted slightly, resulting in that ugly droop you pictured even if the springs and latches are OK.
The cure ? just swap the drivers and passengers handles, side to side, takes a couple of minutes.
Of course in another seventy years or so you'll have to swap them back again ...
Gordon
1941 Highway Trailer K-38
1944 Iron Fireman T-36 Snow Tractor
1986 Nolan Road/Rail trailer
1941 Highway Trailer K-38
1944 Iron Fireman T-36 Snow Tractor
1986 Nolan Road/Rail trailer
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