The CF Bedford Rebuild Begins

Part 8: The rebuild starts - rear door

I wanted the rear door on my custom CF Bedford to lift up (gullwing) but the width of the normal doors together was to wide, so I decided to fit the side door in the back and cut it in half (horizontal).
Originally I planned to use the whole side door frame out of another CF van (I even cut it out), but the frame was so rusty it wasn't worth the effort putting it in so I made some pillars, panels and a door skin for the back of the van.

Once I had a mock up of the size I wanted I next needed to make a door. I started with the original side door frame (removed the outer skin) but noticed the frame actually tapered, so out with the square and cut-off wheel and proceeded to make it square.
I then made a skin with rounded corners which fitted quite well if I do say so myself.
The next part was to hinge it.

After several hours of serious brain straining, this is what I came up with (well this is the parts ready to be welded together).

What isn't shown is the 25x25x3 tubing that completes the hinge, the tube has cut outs and nuts welded into it for the hinges, all holes were drilled 3mm bigger than the bolts thread size - the door adjustment. The bar (tube) fits nicely inside the inner gutter or whatever it's called.

To my amazement the door hinged properly the first time, no alterations were needed, and to think I only went to school to eat my lunch and talk to girls ;) I guess the tech drawing and maths soaked in. Mind you it did take me several attempts making mock templates out of cardboard before coming up with this version.

As the rear door is really a side door, the frame had to be extended 25mm so as to become square (the side door frame tapers), and then strengthened (3mm plate welded across inside top and 18x18x1.5 tube down the sides) mainly for the hinge, this door didn't really need it but the side door will because of it's length. Because the original door skin had to have so much cut out of it (the window recess, door handle and hinge holes), it was easier to make a new door skin for it. The skin went on well, including rounded corners (those corners were tough though).

As the door fitted perfectly the first time the rear panel and new braces were fully welded in place (then coated in PA10). I rounded some 25x25 tubing to the contour of the rear panel; these are braces but mainly support for the number plate recess, you'll understand later.

Next comes the inner door catches.
The first set of door catches I used were from a Nissan station wagon thing (or maybe it was a hatch back), they looked good but on closer inspection were tapered to suit the rear door, as my door is square the latch needed to be recessed, this was going to be a problem, and a problem it was. Took a bit of work but finally made up some plates and fitted them, am quite proud of my latch plates, shame no one will see them.
After doing both the side and back doors I changed the door catches to match the front, for which I used Renault catches. They were a lot less work to fit and tidier.
The door closes (without rubber) with your little finger, haven't got the new rubbers yet so final checks will have to wait until I get them. The rear door (all the doors) will be keyless entry, there is plenty of room in the door so fitting later shouldn't be a problem.

With the rear door hinged, it was time to weld in the rest of the rear panels, of course everything gets checked for fit and tacked then rechecked before being welded (which is a slow process so as not to warp the panels). The roof is still only sitting in place. The recessed number plate holder is only sitting in place; the number plate light holes have been cut out and tested. In this picture doesn't even look roof chopped, but it is, four inches.

Compare this image with the one above, in this image the rear has been fully welded, grounded and a little bit of hammer and filing as the rear section of roof is now welded also. Amazing what different colours does to your mind set. High stoplight has been added but I don't like it, is to wide for my liking so will be redone.

Still to come on the back is the towbar cut out, tail lights (led), keyless entry for rear door, or something to make it open and close from drivers seat. I don't have to have reversing lights or high stop brake light but I will include them, just in case they change the rules at a later date.