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.
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.
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