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Driver's Door - May 25, 2013

The back edge of the door was gapped today. The top 4 inches had too big a gap. The "post" behind the window had a gap that was basically perfect. At the bodyline below the windows, the gap started getting smaller until it was almost zero at the very bottom.

Tick marks were made 7/32" from the door opening edge. The weld proud will assure the finished gap is 3/16" with a minimum of grinding. The tick marks were connected with a piece of masking tape.

The edge of the door was ground to the tape over short sections so the door would not "come apart." Tack welds were put in every two inches after the edge was ground to the tape just past the two inch tick mark. A pair of Vise Grips were clamped on the door and the tack weld was put in.

The tacks were slowly connected with more tacks, jumping around and blowing with compressed air to keep the heat down and well distributed. The same technique was applied to the top 4 inches except the welds were placed directly on the unground edge.

After all the welds were put in, the outer face of the weld was ground flush with the plane of the door. Then the gap was marked on the door for a 3/16" gap. The marks were connected with masking tape and the door edge was ground back to the masking tape. Just like the front edge, the back edge needs some clean up but otherwise looks great.
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