Thomas Minotour Build

[AlphaHare]

Finished and hung the door today. Not sure I'm 100% of the way, but it's hung and works just fine,

I disassembled the upper portion to reuse the skins. I welded my own 1" tubular frame insert rather than cutting down the existing. Note how Thomas used the additional internal web materials to beef up the area under the hinge holes.

After inserting the welded frame, I cut down and reused the inner and outer door skins and riveted it all back together. Placed it in the opening on spacers, drilled for the new hinge, and it's done. I may revisit internal bracing depending on how it behaves.

Thomas bent the frame in two places to make the door match the hoop profile. My extension lives completely in the upper portion.

Next steps are to put the structural piece above it for skin attachment, and also rebuild one of the bus hoops that got cut and moved for the H/C door.

 

[nikitis]

Been thinking about the back door of mine. I'm probably gonna have to slice the door in half similar to your side door because of the angles of my Thomas body. Would look too weird if I did it any other way because I'm cutting my below the windows instead of through them. Will throw off the top in the back by 2+ inches, but not if I cut through the door in the rear and under the windows.

 

[AlphaHare]

Today was 'Use all your Cutting Tools' and 'Victory of the Fein Tool' day.

I cut access to the frames for a 2x2 bar across the top of the door opening, and then welded that in on top of the angle iron. Then I cut out the rib that Thomas moved to make the HC door originally so I can put it back where it belongs. The lower section stays put to support the hinges.

Last thing I'll do is add a 1x2 bar flat across the upper opening - it'll still give me more height that the normal window opening and stiffen up the area. This bay is where the head of the bed is going to be - having the window even a couple inches higher will make a difference.

 

[nikitis]

Fun fun fun. I've started cutting in those same areas myself for my roof raise. Pics soon.