1968 C40 to K40 pickup project BlueMule

[Old_Green]

The grey door has a little less rust in it, and now that I have the door skin off, I can fix the hinge from the inside, so Ill use that door for the hinge side and keep the majority of the good metal. I will also beef up the door at the hinge bracket.

After much consideration I picked where I wanted to cut the doors. I scribed the cut lines then added tape with direction markers for which side of the lines to cut. I did some other work for a while, then came back and double checked my math. After about 15 times of doing that, I might be ready to cut.

I cut the grey door 7 inches from the latch edge of the door, cutting on latch side of the scribe. This will leave the entire regulator mechanism on the original metal. Then I cut the blue door 13 3/8 inches from the latch edge of the door, cutting on the hinge side of the scribe. I then cut 3/8 of an inch off where I couldn't flange the metal. This way, I can overlap the 2 pieces where they are flat, and butt weld where they arent.