The CF Bedford Rebuild Begins

Part 11: The rebuild starts - side door

As the Bedford side door needed to many patches added (hinges, window, handle, bottom edge), it was easier to make a new door skin for it.
The CF side door has a strange set up where as the edges are at 90 degrees to the panel, most doors have the door skin hammered around the frame, so this is what I did. The skin was folded up and the corners rounded on the skin and on the frame. The frame was shortened 3 3/4 inches (not the 4 like the roof chop) as the gutters which have been removed dip into the door gap, so keeping within a 3mm door gap.

First up the rust had to be removed, the rust was cut out and panel steel welded in, the worst bits were across the bottom as well as the sides (where the skin went). The frame also had to have gussets welded to the chop lines for added strength.

The frame itself was also strengthened by means a 3mm plate welded across the top of the door frame and 25x25 tube welded down the length of the door (for the gas stays). The door catch holders were made up and welded in place. The solenoids were set below the catches with the rods set in place. On testing I found the door flexed a bit so added some 3mm plates beside the catch for strength.

The door skin has hammered on and checked for fit. It fitted the hole well but the back bodyline was out of alignment, hence the chalk line, a visual line so I could re-hammer it. The wonky line was a result of someone welding up the holes from a moulding or something (van could of been a camper at one stage).
Isn't it strange how the colour can give a different effect!

UPDATE:
I am thinking of changing the side door, as the van is lowish I keep banging my head on the damn thing. I'm only 5'10" so any average to tall people will be knocked out for sure, is very solid door.
Plan is to use CF front door hinges for the side door and will change the latch system (that's going to be fun) to the same catches used on the front (Renualt). Still internal hinges and shaved, just open like the front door. I know the front door hinges are not a full 90 degrees but would be better than banging my head all the time. I wouldn't recommend using the front hinges if using the van as goods vehicle.
Now to find a front pillar ...

UPDATE UPDATE:
Am no longer going to change the side door :rolleyes:

UPDATE UPDATE UPDATE:
I did change the side door