1950 Liner "Weeble" - Rebuilt the door-in-a-door from scratch - Part 2
Posted 03-25-2018 at 06:50 PM by Bowmans
The next step was to attach the outside sheet to the sides. I used a small, hand-held duct bender to make the bends on the sides. Then cleco'd and solid riveted using the (oh so handy) plier like rivet tool from VTS. This tool was such a time saver.
Sheeting the door sides:
Test fit with sheeting on sides modeled by my wife:
Next we cut out the top outer skin and attached. The bottom piece we wanted to wrap around to the inside (not sure if this was the way they made originally or not). We didn't want rivets at the base. We trimmed the frames to match the curve at the bottom. Then had to bend the bottom sheet in two places about a 1/2" apart without a bender. We used a piece of wood cut to match the bottom two bends, clamped and used a board and rubber hammer to get the shape.
Top sheet on and bottom sheet being cleco'd:
Now it was on to building the door-in-door. We started with the same frame rails and cut them to fit inside one another.
Door-in-door frame sitting in the door:
Cut and bent a sheet for the front of the dootr-in-door, cleco'd and riveted.
Top sheet on and bottom sheet being cleco'd:
Here is an image of both doors together:
It took two weekends to build frames and sheet the outside of both a door and door-in-door. We haven't sprung and put the inside sheets on the door. This will happen after the shell is on the new frame. We have put the sheet on the inside of the door-in-door and put the little rain guard above the door-in-door. We have also put on a set of stainless steel hinges. They required a good bit of bending to make fit right but the door-in-door opens nicely. There will be more pictures later of the finished door. Now on to the belly pan.
Sheeting the door sides:
Test fit with sheeting on sides modeled by my wife:
Next we cut out the top outer skin and attached. The bottom piece we wanted to wrap around to the inside (not sure if this was the way they made originally or not). We didn't want rivets at the base. We trimmed the frames to match the curve at the bottom. Then had to bend the bottom sheet in two places about a 1/2" apart without a bender. We used a piece of wood cut to match the bottom two bends, clamped and used a board and rubber hammer to get the shape.
Top sheet on and bottom sheet being cleco'd:
Now it was on to building the door-in-door. We started with the same frame rails and cut them to fit inside one another.
Door-in-door frame sitting in the door:
Cut and bent a sheet for the front of the dootr-in-door, cleco'd and riveted.
Top sheet on and bottom sheet being cleco'd:
Here is an image of both doors together:
It took two weekends to build frames and sheet the outside of both a door and door-in-door. We haven't sprung and put the inside sheets on the door. This will happen after the shell is on the new frame. We have put the sheet on the inside of the door-in-door and put the little rain guard above the door-in-door. We have also put on a set of stainless steel hinges. They required a good bit of bending to make fit right but the door-in-door opens nicely. There will be more pictures later of the finished door. Now on to the belly pan.
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