drivers door repair
 

Working on the Drivers door, and decided that hey, I have sheet metal here, lets repair the bottom of the door. Patina trucks can still have this bit replaced without the absolute travesty of fresh metal and paint showing somewhere (=

I cut out the nasty bit and did my best to form a patch... its not perfect, but it's here, and it was free!

I also found the old window... it was rattling around inside this door along with 5 pounds of dirt!

Then I realized easy access like this is great for fixing the rest of the door... the hinge side was all pushed in, the lower hinge area is a disaster and was farmer-fixed... so this led to that.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

For not being a body man Dave you sure tackle the sheet metal work and get good results … well for a patina truck .
But the more you work the more experience you gain and the better the results .
Won’t be long and you’ll be ready to go for a primed finish and then the fun begins.
Yah I know you’re going for patina finish on this truck, but some day the next project you’ll be that much closer with your skills to go to the next level.
Congratulations keep at it.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks, Glen! I'm definitely just jumping and getting some lessons learned. I don't have a body work mentor here so I'm just going at it. It's fun AND stressful, but I WILL get this truck on the road!

The drivers fender eyebrow is essentially non-salvageable unless you were fully equipped with tools and skills to form patches and I'm not. But it will hold headlights now, and I may tinker with it a bit to improve the looks a touch more.

Working on the door hinge area
 

While I had the door apart, I was able to fix some "creative" body work done by previous owners and get the hinge side jamb area to more closely resemble what it should be, vs. being all caved in.

I had a piece of steel bar stock to use as a dolly that was the right width. You can see in the second photo how wide this area had become by past hammering, vs the lower portion of that photo showing how narrow it should be.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

The hinge corner on this door was BAD. Someone before me used C channel, steel rod, and some nuts to repair it, which wasnt too bad considering it was basically a quick fix, but it wasnt good enough for me.

I cut that garbage out, and I'm welding in some slightly better garbage:lol:

My donor was much better, but still broken, so I first made a thick, strong backing plate to hide behind the cracked sheet metal. After I drilled and bolted it in, I welded it to the back of the hinge support in multiple places (not pictured) From the outside, it will appear to be in dire need of repair, but magically strong somehow!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Once this hinge was fixed, I could take HOURS to get it positioned the best I could based on measuring another spare door in like 20 places... It's probably not a perfect positioning but its better than what I had!

I also had to replace a little corner of the door but I didnt photograph that bit.

I'll have to experiment with blending this paint in, but the good news is that I can do that some other time, when I have a running, driving, stopping truck.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Nice job on the repair!! That ought to hold for a few years :)

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks! I think it will keep the door on, at least...we'll see if it closes.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Before I could continue on, I needed to add a corner to the door... there was simply just no metal here whatsoever. I cut it clean, made patch and did my best to be patient with the tacks. it wasn't a smooth area to begin with, but I didn't want to cut more painted surface away than necessary.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

The lower corner I attached seemed to be at a bit of an angle to the rest of the door. The missing sheet metal at the bottom certainly wasnt helping with rigidity... so I came up with this solution. I clamped bar steel on both sides until the corner and door were flush with each other, and tacked the door to the steel on top to keep it there while I attached the door bottom patch.

It worked well, and held just fine while I got the lower patch fitted.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Any more progress lately ?

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

I've been on vacation for a couple of weeks, so nothing has really been done. Before I left, I fitted the patch I made and started tacking it in.

I realize that I didn't fit any drain holes, so I'll have to sort that out, somehow. I still need to clean up the corners, but I think it will be a functional door at least, and I'm glad I can hide my beginner-quality work under a door!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

looks good.
when I do patches I fit the part and hold it in place with magnets, then do small tacks starting at one end with a tack, then go to the other end with a tack and then one side then the other side. this ensures the part doesn't get moved as the welds pull the metal when they heat and cool. I try to tack not too close to a magnet as the magnetic field disrupts the mig welder. then once it's tacked in a few spots I ensure the fit is still like it should be and adjust as required. then I place a tack half way between the existing tacks. letting each one cool, an air blow gun can help this along. tack, cool, tack, cool, placing the tacks half way between the other tacks and working at opposite areas between tacks and checking fitment. if I have access easily to the back side of the panel sometimes I will hammer on dolly right on the tack weld when it is still cooking hot. this expands the weld and when it cools the panel doesn't shrink or pull so much.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks for sharing the tips!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Since I didnt want to cut into the door front too much at first, this section had very little integrity, looked like crap, and needed to be replaced. This also let me smooth out the line at the bottom of the door where the replacement corner meets the rest of the door.

Nothing too exciting, but I'm documenting the steps!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

if you plan to grind the welds smooth I would recommend a grinding disc, like a hard carborundum one, because the flap discs that lots of guys use, including myself lots, tend to remove metal from surrounding area when you get close to the parts being level.

question, why does your thread come up smaller than every other thread I keep track of?

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

I have the best luck with a 36 grit 3” roloc disc very very slow to get the metal smooth at the weld joint and then a fine grit one to smooth it up, then a file to get flat if possible. Speed has never really worked out for me in welding work.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Nearly done with this door, it's patched up and should be serviceable! I think the next door is getting a repop skin because I don't have the skills to use the primitive metal shaping tools I possess to make a suitable patch. If I had a mentor here and was taking metal shaping classes, maybe? But they'd get me on machines anyways, I'm over here using techniques from the 1920's or something (=

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

very nice work!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks, I think it's not too bad for just saying to hell with it and giving it a try. I could stand to own and learn how to use a shrinking disc i bet... they seem like magic for sheet metal!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

'20s or not, looks like you did really well!!!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

your doing a fine job. each time you fabricate something you get a little better and gain more experience....as for that shrinking disc....I have one.it works, but the pros make it look easy, its something that takes time to get good at it.like everything else, its also not something you used on everything. but its another tool thats nice to have

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks Gents! Learning as I go! I goofed around with a torch and wet rag today... that will take some learning too.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Wanna bet??? HAHAHAHAHAHA!!!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

You keep saying you don’t have the skills but the pics tell another story.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thank you! I'm a good photographer ;) I've also seen what guys here are capable of, and it blows my mind! They just slap in some sheet metal and it looks like its been there the entire time. I won't be satisfied unless I can complete with theastronaut.


I think I made a solid effort. Learned the consequences of not cutting away enough bad metal (some thin spots that are now inaccessible from the back and I don't want to cut another patch). Cut away the bad metal, everyone! You can't weld to it! :waah:

Fortunately I picked the right truck to practice on, and it looks no worse than the other panels with 60 years of truckin on em. Knowing how bad this all was before, I'm pleased with the outcome so far.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Dave you’re doing great fab work keep at it .

BTW Happy New Year !

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

if you have an old steam iron that puts out pretty good heat still you can try that like a shrinking disc. the nice thing about the shrinking disc compared to a torch is that it only heats up the high spots and a torch is also easy to overheat. heat and use a wet rag or sponge but only heat enough to make steam when you apply the rag. an iron will likely take longer but probably get the same result. it really comes down to getting the sheet metal work as smooth as possible first. hammer and dolly technique is a good skill to practice on with some old panels. there is a good little read called "the key to metal bumping", it's an old book but teaches some techniques of how to start removing a dent etc. there is an online pdf for free I think.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

you do good work!

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Oh yeah I need to do some reading for sure! Good suggestion

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks! Once I shot it in a matte primer to keep it from rusting, it definitely looked better

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Switching gears for a bit just to keep things interesting. Wiring up power, relays, and PCM signal for my '94 T-Bird Junkyard fan.

I've had these bits for awhile but didn't get started on the electric fan wiring until I could decide how I wanted to connect the wires and what type of power/fuse block I could score from the yard. I landed on some delphi style weather pack connectors for the PCM fan control wires and key hot 12v power, with one plug for the low speed and one for the high speed.

I had to add these wires into my LS PCM and did so back when I was reworking my harness. I figured if I DIDN'T use electric fans, then these wires could just be tucked, but I definitely wouldn't want to go back and do this later!

I snagged this power distribution block from a junkyard, and it has 100A and 50A fuses, which is perfect, and if I want to drop the fuse amperage, just file away some metal on the sides! I'll be using this block to provide battery 12v to the fans as well at the headlights, and I'll be controlling the headlights via relay instead of having them pull 12V through the old headlight switch. Once its taped and loomed it should looks decent. I wish they didn't use all these bright primary colors in the relay wiring, but I didn't want to rebuild the whole thing so I'll just hide it.

I'm trying to retain the ability to remove the entire front clip, wiring and all, so I've got some larger connectors on order to create a harness of sorts for the front clip electrical just as they came from the factory.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

While i wait for more electrical parts to arrive, I returned back to the drivers door area, as there are probably 20 more little jobs waiting for me until I have a functional door that can close securely.

Next up on the list was making a new captive nut so I can get hinges installed, test fit the door, and fine tune the fit the best I can without removing any more factory paint.

I used some mild steel for the nut, drilled and tapped for 7/16 fine thread, then sized it to fit into some square tubing. The tubing makes it easy to capture the nut after some cutting and bending. Then I drilled holes in the pocket face and tacked the nut in, making sure to center it first.

As you can see, precision wasn't really necessary here, as it's all hidden, plus the tubing prevents the twisting force far better than the factory sheet metal cage

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

nice job. gotta do that to a few doors i have too.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Thanks, it's one of those chores that doesn't result in a cool new feature, but it must be done. The tubing made it very simple though! 10/10 would recommend.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

After searching for YEARS, all around the country, I've finally located a front clip to replace what I have. I got to practice some metal work on mine, but this clip is just in better shape, and more importantly, its an excellent match!!

Even more awesome is that instead of having to ship it here from heaven-knows-where, it was only 2 hours from home.

I prefer the 59 emblems too, so that's an added bonus.

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

Nice score Dave !

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

looks to be in great shape. did you score the box too?

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

was the seller planning a perimiter frame under it and gave up possibly?

Re: 1958 Apache Big Window Loooooong Bed "Lucky"
 

It was a long box with mis-matched fenders, so I left it there. If it were a perfect shortbox, then I'd have brought it home!

Actually, they are using the cab and frame to make a '57 instead so these were just unwanted leftover dropped on a ford car frame. Win/win, as I needed specifically what they did not! I wouldn't have said no to two nice doors though (=