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09-02-2009 10:15 PM More Door Work
Tonight the bead at the bottom of the door was modified. This bead will interfere with the motor mount and the drive tube on the power window unit. After cutting it out, two tabs were cut out and welded in to bring the ends of the opening up flush with the inner door panel. Then a rectangular patch was welded into place. After a bunch of grinding, the panel is ready to cut.


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  [Entry #261]

09-01-2009 06:21 AM Wiper Motor Lower Support Bracket
I remember reading a quote once. I think it was by Lil' John Buttera. He was asked how he made some of his parts. He responded something to the effect that he starts with a chunk of metal and cuts away anything that does not resemble the part he wanted. I like that concept.

So, tonight (since I didn't feel like working on the door!) I tackled the lower support bracket for the windshield wiper motor. The kit had a strap which was supposed to hook into the stock dash somewhere. Since the stock dash is gone and the wiper motor is mounted on a custom made main bracket, the strap brace wasn't going to work.

I started with a chunk of 2 x 3 rectangular tube since I had it on hand. After a bunch of cutting, grinding, heating, bending, and drilling, this is what was left. Elegant in its simplicity, if I do say so myself. It now will securely mount the lower portion of the main bracket to the brake pedal support.


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  [Entry #260]

09-01-2009 06:13 AM Cowl Vent Trough and Hinge
The cowl vent had a trough to catch water. It had a tube which I assume had a hose connected to it at one time in order to direct any water to the outside of the car. The trough also had parts of the hinge assembly attached to it.

The spot welds were cut out and the trough assembly was removed. It didn't take up a lot of space, but every little bit is going to help on the AC install. Its removal will also allow for a bit more rust removal.


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  [Entry #259]

08-29-2009 11:23 PM Power Window Prep
I decided to do this side a little different from the passenger side. For starters, I didn't create big parts which required removing sections of the door so the new parts would fit

I started by cutting the slot in the stock sheet metal to allow for the top of the power window assembly to mount there.

Then the area was cut on three sides, forming a flap. The flap was flattened and re-welded.

The inner brace had the 8 spot welds cut. The brace was then removed and discarded. Holes were filled. There are still 3 holes to fill, but I was running out of time.

Most of the cut locations were marked. The next time the cuts will be made, the section flattened, and the flap welded back into place creating a recess for the power unit.


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  [Entry #258]

08-29-2009 11:08 PM Install the Driver's Door Front Channel
The pocket for the hinge mounting plate needs to be modified to clear the window channel. So does the pocket for the door strap. The hinge mounting plate also got trimmed slightly. The channel fits now with a full range of adjustment. Time will tell if this is good enough.

Cutting was difficult due to the cramped space. Also, due to the location, it is difficult to see the parts and operate the air tools at the same time. Some of my air tools had the safety trigger taped open to ease operation


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  [Entry #257]

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