Top Choppin
Hotshot
Joined: Oct 2004
Posts: 15,882
Likes: 88
From: Durham NC
I don't know what MT plans to use for filler, but IMHO it would make most sense to use donor pieces for the door and windshied header since it would be difficult to duplicate the profile and inner structure by hand. Not too many make the extra effort, but you also should open the skin on the windshield posts and weld the inner structure back together for safety, it's the only thing besides your head that would be supporting the roof in the case of a rollover, I wouldn't want to rely on just the outer skin to do the job.
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Posting Guru
Joined: Apr 2004
Posts: 1,074
Likes: 0
From: Northwestern PA
I actually plan on using the piece that I removed fron the rear of the door post. It is really close to the same size.. A donner door would work also, but I see no problem using this piece. I am using pieces from a donner cab at all the edges for the chanels.
Mike
Mike
Originally Posted by NJ239Y
How do you plan on expanding the tops of the doors? Would using a piece from junk door help, or would it be easier to just fill in the gaps with sheet metal strip? I always thought that the gaps would be a lot larger than what you show. Good luck! Looks like you' re doing a clean job!
Posting Guru
Joined: May 2002
Posts: 1,495
Likes: 2
From: Northwest Fl
You're making a tough job look easy. I have never seen a step by step process and have always thought it would be tougher than what it actually is, though it still takes considerable tallent/skills the process is indeed interesting. Cutting the front windshield could be a little delicate, but maybe not for a pro. Nice work.
Cargo Master
Joined: Jan 2005
Posts: 2,497
Likes: 5
From: Tucson AZ
not to disparge Mike's skills in any manner, but careful planning and thinking ahead is what makes this job ''easy'' I have found over the last 30+ years that thinking is at least as important as doing, it never hurts to have advice from an ''expert'' and the unknown can be very intimidating. go for it!
Hotshot
Joined: Oct 2004
Posts: 15,882
Likes: 88
From: Durham NC
Cutting it apart isn't the hard part, putting it all back together and keeping it straight so it looks like it came that way, THAT'S the hard(er) part and is where the real skill comes in. It's real easy for a seam or two in a large unsupported panel like a top to get away from you and warp like a pretzel. Keeping the assembly in line like Mt54 is doing with temp bracing, jigs and clamps, keeping the weld heat buildup to a minmum by skip welding and hammer welding the seams to stretch out the shrinkage as you go is the key. Our trucks with the equal profile straight pillars and door frames make it a lot easier job than most fat fendered vehicles. The windshield can be cut relatively easily or the top of the windshield frame could be slit open and the windshield top slid up into the roof depending on the amount chopped. You can cut around the rear window and take the piece out below the frame so you don't end up with a mailbox slot rear window and no glass cutting needed. The door windows are the easiest, just don't roll them up as far!
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