2009 at the Hammond Barn

[Phil Waterman]

Need I say more, looks like you are making real progress.

Though I must say using three people to put the nose on is cheating. Though I bet it went on quicker that way.

Cheers Phil

[RHClarke]

Originally Posted by Phil Waterman

Need I say more, looks like you are making real progress.Though I must say using three people to put the nose on is cheating. Though I bet it went on quicker that way. Cheers Phil

Phil, I took advantage of the available "horsepower" at the barn. One more advantage of working with a crew like the Hammond Quartet. Everyone at the barn is curious about the HUP as it differs in so many ways from the "real CMPs" as Bob and Grant put it...

Of course, we could have wheeled the HUP into the barn and use the overhead gantry system Bob installed, but the sunshine and fresh air was too nice to pass up.

Just another great day at the Hammond Barn!

[Bob Carriere]

Finally got to the sheet metal part of the project.... one I dread being not very familiar with body work and the proper way of working sheet metal. Oh don't get me wrong... I read the books... seen the video... the proff of the "putine" is when you start to do it....

My cab 11 doors are not too badly rotted... just the bottom outside skin will need replacing. But before tackling the good one I felt I should practice first. Being lucky enough to have acquired the cab 12 from Ajax.... affectionately known as TED'S truck which is a 42 something cab 12 and theone I got from Doug Weatherstone (spelling?) a known cab 12 I removed all the doors and started to practice.

Grant was my able assistant and sometimes lead hand in this venture. We started by dismantling the doors many screws, bolts, etc..... and thereby removed the inner skin, the lock mechanism, handles, etc..... all to be saved in jars and labelled Zip lock plastic bags.

The doors were really "Hollier than Thou" in the bottom quadrant.... see the attached pictures.

It became obvious that we would need some 14 gauge sheet metal bent to shape by a patient and understanding fabricator.

IN the disassembly stage we discovered that the "wedge" that aligns the doors when shut latching mechanisms in the door and the striker plates that holds the door closed all had to be coordinated..... see pictures of the wedge on my cab 11.... the various striker plates... and the latch the we obtained from Mac Auto.... the Ford parts palce in Niagara Falls. After all if the door handles on a Chev cab 11 are Ford... why wouldn't the latch mechanism...?

We also found the pot metal tubes that fit inside the top of the cab 11 doors... the ones that accept the rod form the canvass curtains also at Mac Auto.......

So let me end this one posting with a series of pictures... more info to follow.

First two pics shows the inside, once the inside panel was removed and the outside condition. The sheet metal and the door frame was completely eaten away by metal termites....

The third is a seperate door with same affliction....

Boob

[Bob Carriere]

See pictures below.....

The good one is from the cab 11....the bad one from a cab 12......

These Wedge parts are available from Mac Auto Ford......

The next Photo is where the wedge fits in the door.... in most cases the sagging of the door has caused some extreme wear of broken parts....

...and the resulting damage to the wedge,,,,,

Now inside the door frame is this ..Ford again... latch which is usually broken...

Now for the latch removed..... in a number of cases at least one of the rubbing blocks willme missing ... having fallen off when the tab broke.




on to the next part....

[Bob Carriere]

The following are pcitures of the replacement latch mechanism

... the actual lock mechanism and NOS cab 11 door handles both inside and outside.... you will notice the chromed repro from MAc Auto... again made in China butr very close to the original.... see back side for difference in casting... once sandblasted they will take OD paint quite well....

One more photo showing the replacement pot metal tubes for the side curtains.... they are slightly shorter but will be made to fit... tweo are needed per doors.....

Last is profile look at inner and outer handles....

[Bob Carriere]

Doors skins not fore skins you neenee....

Removing the door skin at first appeared fairly easy since some doors were so rusted that we did not detect any spot weld..... has we progressed to areas not so rusted we found that the folded over outer skin had in deed been spot welded...... spot weld cutters.... very sharp samll chisel and the typical abuse of a good screw driver had them popping in no time......

soem doors were so corroded and thenetal so fatigue form years of door slamming that the skin and part of the frame was coming apart.. ley me show you.....

Here is a crude sketched of the profile of the door frame and its weak areas...
the frame is folded back onto itself to provide an area for the door skin to be folded and spot welded to...... with rust and constant door slamming the over folded area breaks loose at the arrow. Far too complex to reproduced we have opted for a simple U bent frame and we will cut out an exact duplicate of the folded over part except ours will be spot welded to the frame and we hpe more solid. The oly part that is different on the frame is the top part which is covered by the external door skin and is actually 1.75 inch wide plus the tickness of a 14 guage sheet.... in the case of the top part the metal is actually folded inside the U shape of the frame.

So we got our courage and cut off the bottom of the door.... you can see the repro part Grant and I fabricated. We simply made a pattern out of old 2x6 lumber and heated and bent the U shape frame by hand.... once hot enough it bacme very plastic..... yeah the wood charred but that is Ok....

We made the cut up to the good metal on the curve side..... and just below the hinge position so as to maintain dimensions. Grant measured everything 3 times beofre cutting and we still had some complete doors to fall back on in case of dimentia....

In between giving me a hand Grant was busy redoing his cab 13 door.... butr that is a whole different story....

[Bob Carriere]

The semi finished product..... still some touch up grinding... don't want ot make it too perfect or it will not look original.....

Concerned with getting the door the exact size it was before.... Grant had the excellent idea of bolting the inner skin back on as a jig for positioning the replacement bottom part..... sure made things easier....

Of course being Public servants and overly cautious we opted for a re-enforcement plate on the inside the frame to give more strength to the door frame.... we also had no wartime metal shortage.... I predrilled the inside plate and welded from the inside.... with proper penetration it almost looks like spot welding work.....

The other side was also re-enforced from the back side but we had to cut out the space for the hinge...... we had to cut out other wise the hinge would have been 14 gauge out of alignment,,,,,

Final picture....... no bad for a bunch of government paper pushers.... of course we still have to replace the large plate at the bottom.... half was cut away as being too rusted.... but it was supper time and it was time to go!!!

Thanks to Grant for the helping hand... to Rob who keeps helping around the barn thereby allowing me freedom to work on the door and for Barry's inspiration........

More will follow but for now I must close the door on door repairs......

Bob