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Project: Magic Doorgate Guess what, I ain't dead! :flipoff: Just been taking time off from RC's to do other stuff. Some of that stuff requires welding, so I broke down and bought an Eastwood MIG 135. That's the baby model, that runs on 110V (more on that later). The Magic Doorgate works like a tailgate when you turn the handle one way, and like a door if you turn it the other. (This for those too young to remember station wagons.) Those of you with long memories will recall the old Country Squire wagon I built back in what, 2011? Anyway, that featured a working Magic Doorgate, and I said to myself, "Self, how cool would it be to build one in full scale? Pretty awesome, self. You should totally do that." So, conversation over, I started in. First step is to build the left lower hinge, to change it to 2-way operation. Okay, that's second. First is to tear it apart: http://i103.photobucket.com/albums/m...psrdfiycjp.jpg Thanks, Ford, for using the Devil's Own Threadlock in there. MAPP torch to the rescue. Then we can make with the welding: http://i103.photobucket.com/albums/m...pscgcuhaph.jpg Wait, that's finished. Okay, I didn't take pictures while I was throwing sparks. Mostly this has to do with my mood after dealing with the Devil's Own Threadlock. What you're looking at is a heavy-duty gate hinge (from Lowe's) welded to the chopped-up factory lower hinge. Had to take care to keep the spacing right, otherwise the tailgate wouldn't fit back on. That cross marks the center for the big bushing, so I'd know where to drill the hole. http://i103.photobucket.com/albums/m...psgb3lovig.jpg This is the business end of the hinge. http://i103.photobucket.com/albums/m...psd0qxnizp.jpg Test fitting, with the tailgate notched for clearance. http://i103.photobucket.com/albums/m...ps8mfmyxxb.jpg Primed and reassembled. No more driver's side latch (for now) or passenger side cable (forever). http://i103.photobucket.com/albums/m...pszdw3h6k4.jpg All closed up. It works nice and smooth so I know I got the center in the right place. If not, there's a ton of adjustability built into the factory hinge. I just lined it up with the unpainted shadow of where it used to be, and it was spot on. I'll be doing this in stages as weather and back health permits. I find I can do about 3 hours of this a day before I've had enough, so don't expect lightning progress. I'm waiting on latches now, supposed to be here Tuesday. Some would say starting early is a sign of an immature mind (no argument) but I saw a weather opportunity and took advantage. As far as the MIG running on house current, it needs 20A at its max setting (which I used for this hinge) and the garage only supplies 15A. So I plugged it into the emergency generator. Stay tuned for more updates! |
Re: Project: Magic Doorgate Today's update (last til next week, weather permitting): Started on the left upper latch/hinge base: http://i103.photobucket.com/albums/m...psyddn2pgw.jpg It's a short chunk of 1" square tube welded to the original tailgate striker. This is the test fitting. Can you say booger welds? http://i103.photobucket.com/albums/m...psqrxtjvdb.jpg Aligning the lower hinge http://i103.photobucket.com/albums/m...psocawsimc.jpg The cats are really ticked off that I stole their toy for this project... http://i103.photobucket.com/albums/m...pssm3254nu.jpg But now I can see that the alignment is on. Weird that I used a laser when the tape measure has yet to make an appearance, but that's me. http://i103.photobucket.com/albums/m...psgmervqi9.jpg Base cleaned up as much as possible. As I'm still learning to weld, I'm pretty happy if I can get "talented ape" results. So yeah, not bad for an ape. The tailgate will need a big notch to clear this, which hasn't been done yet. Once the latches arrive I can do that. |
Re: Project: Magic Doorgate My Caprice Wagon has the back door you are trying to build. My question is why? I have doubts about the hinge supporting the weight of the tailgate. And more importantly what you are doing ,at least to this point, is very unaesthetically pleasing. If you like I can get some pics from my Caprice. |
Re: Project: Magic Doorgate The why is easy. I'm an old fart with a bad back, and loading heavy stuff over the tailgate is getting really old. With it open, door-fashion, I have a clear path to the floor without bending over. Also, because I can. The weight of the gate itself shouldn't be a problem. There's no glass in there and it only weighs 40 pounds. I have plans for aesthetics, although the solution to the left lower hinge is still rattling around inside my head looking for the right neuron to hit. If nothing else I'll just paint it body color and hope it doesn't stand out so much. And, if it all turns to cack, I can put another tailgate on there. This all bolts on with no mods to the truck bed. |
Re: Project: Magic Doorgate Well, I told myself I wasn't gonna, but I went to one of those big Black Friday sales. They had tailgate handles 100% off: http://i103.photobucket.com/albums/m...psbzerh6ye.jpg Everything went just fine til I did the final grind-off, then the tailgate gonged. It's got a depression the size of a dinner plate below the patch (too much heat I guess). So I'll go in there with a spoon and ding it back out. The patch is from the wheel-arch panel that I'm going to replace this spring (rust). I won't need to go all the way to the character line with that, so I stole a chunk of it for this. Which is how the character line looks right. Not bad for an ape, but still learning. And for anyone who thinks the new lower hinge looks weak, it supports my big ass just fine. |
Re: Project: Magic Doorgate Nice to see you are still around. Glad to see that you are doing something different and say "eff it, I'm still doing it" to those who question your methods or reasoning. Looking forward to your end result. |
Re: Project: Magic Doorgate Getting closer all the time, Dean. More progress on the WTFGate: Took a break from the normal Black Friday routine of cowering under the bed, and braved the hordes of people bravely overloading their credit cards. Fortunately the hardware aisle was pretty empty (personally I'd love a big bucket of nuts & bolts for Christmas, but apparently I'm in the minority there. Should have stayed home, as this attempt is sort of a bust. Or practice, if you want to look at it that way. http://i103.photobucket.com/albums/m...psdzns4bb2.jpg This is the handle end of the release mechanism, which connects to.... http://i103.photobucket.com/albums/m...psy85thtbf.jpg ... what I'm calling a multiplier. It works, as far as it goes, but there's far too much lost motion with the primary linkage, which is 1/8 rod with Z bends on the ends. This will be replaced with twin cables, which acting in tension should have zero or a lot less slop. Not to mention being a whole lot easier to install. Now for the wailing and gnashing of teeth: http://i103.photobucket.com/albums/m...psc53edlm0.jpg WHAT IS THAT, A DOORKNOB FROM A PUBLIC TOILET?! YOU SHOULD HAVE USED (insert alternative here). Yes, it's a common household doorknob, for the simple reason that they operate in two directions. WHY DID YOU PUT IT OUTSIDE IT LOOKS HORRIBLE! Because that's where door handles belong. Also, if I put it inside it would have to mount to the access panel, and good luck setting up cables when it's all buttoned up. Also, IDGAF. Anyway, I'm all ready for latches. |
Re: Project: Magic Doorgate I like it man, very cool project! |
Re: Project: Magic Doorgate Oh, what a happy day! The postman brought me some door latches: http://i103.photobucket.com/albums/m...pssezeb0p4.jpg Now here's the thing: These are door latches, not magic doorgate latches. Which means the release mech works by pushing, like with a door handle. I need to pull. Fortunately, with some ball ends and the door locking bellcrank, I can make a reversing mech that works with a pull cable. Like so: http://i103.photobucket.com/albums/m...pst8ftrex9.jpg Shown installed in a channel made from square tube So now it's time to butcher the tailgate: http://i103.photobucket.com/albums/m...psvuubjici.jpg And throw some sparks: http://i103.photobucket.com/albums/m...ps3dd2yecw.jpg Tack welded in. I know, it's sort of a mess. http://i103.photobucket.com/albums/m...pslv7m0tlo.jpg Proof of concept http://i103.photobucket.com/albums/m...psg4ekp36r.jpg Had to chop the doorjamb a little... http://i103.photobucket.com/albums/m...psv49sxgsy.jpg ... and the taillight got a trim, too. I'll pretty it up later. |
Re: Project: Magic Doorgate What's your plan for cleaning that up and making it look better? |
Re: Project: Magic Doorgate I can't really clean it up, but I can damn sure cover it up. I've got some 24-ga steel for that. The good news is that the right lower hinge/latch will sit inside the skin, invisible. |
Re: Project: Magic Doorgate Not much progress today, I about killed myself with yesterday's frenzy. But I did manage to get some stuff done: http://i103.photobucket.com/albums/m...pstrkj70if.jpg New striker installed. This will have to be repositioned as it's 1/4 inch too far out from the bed floor. Yes, I burned the paint getting the damn bolts loose. http://i103.photobucket.com/albums/m...pssfu8ihoz.jpg Trimmed the latch mounting panel to fit the tailgate, and bent up a tube for the release cable to run in. I'll have to cut the inner tailgate for access. http://i103.photobucket.com/albums/m...psiwiffysp.jpg Cables replace rods for the release mech. Everything works much smoother and more consistently now. The springs are there so the sliding factory latch can release first, then the spring latch will pop the gate open. http://i103.photobucket.com/albums/m...psbkn2hk1y.jpg Brace for the left upper latch/hinge and an emergency release cord. This will be tucked behind the pad on the tailgate. |
Re: Project: Magic Doorgate Between yesterday afternoon and this morning, I got some stuff done. http://i103.photobucket.com/albums/m...psqcvsqewh.jpg Made a hole... http://i103.photobucket.com/albums/m...psxcrifixc.jpg Tacked the right lower latch in place. At this point the doorgate is mostly functional. I have to pull this latch manually, haven't hooked up the cable yet. That's what the big hole above is for. http://i103.photobucket.com/albums/m...psnrswfjvw.jpg My CAD (cardboard aided design) is updated weekly by the pizza boy. http://i103.photobucket.com/albums/m...pszhbax86o.jpg Made a start on the latch cover. This won't look so huge once it's painted body color. http://i103.photobucket.com/albums/m...ps7xdh58uo.jpg After welding and some grinding (needs a bit more of that, but this is where I stopped today. |
Re: Project: Magic Doorgate I started out the day thinking I'd do a couple small things, and ended up damn near finishing it. When I get on a roll, I keep it rolling. Paying the Quasimodo price for it now, though. But ya know what? Totally worth it. http://i103.photobucket.com/albums/m...pstvbkoubt.jpg First, I installed my cable guide tube, ran the cable, and tested the mech. Working good enough to button it back up: http://i103.photobucket.com/albums/m...ps7delfscp.jpg The cuts were a bit ugly, so I've got a bigger gap than I care for, but it's tacked back in. Needed a bridge plate on the right outer edge. As this is inside the tailgate where only I will see it, I'm not too fussed over it. Bedliner will cover a lot of sins. After that it was only a matter of fine-tuning the striker placement, which took about 2 hours longer than it should have. But finally: http://i103.photobucket.com/albums/m...psjfoha2cc.jpg Door... http://i103.photobucket.com/albums/m...psago2a1dp.jpg .. gate. And yes, after I got to this point I spent half an hour going "door...gate...door...gate..." Now to pretty up the exposed latch and boink that dent back out. |
Re: Project: Magic Doorgate There is a whole lot of stuff you jam in one little tailgate , Or door. LOL , nice to see custom fab work. "thumbsup" |
Re: Project: Magic Doorgate I applaud your creativity to build something that will help make your chores easier on your back. "thumbsup" |
Re: Project: Magic Doorgate Cad .... lol. Never heard that reference before. Nice work. |
Re: Project: Magic Doorgate Love all the work going into this tailgate setup! |
Re: Project: Magic Doorgate Excellent job Stu, good to read your most entertaining posts again. |
Re: Project: Magic Doorgate :shock:...you're alive Stu?! :flipoff: I tell stories about you everyday to anybody who asks about the International semi I have in my office. "thumbsup" The legend is at it again. By the way, no Facebook account yet? :flipoff: |
Re: Project: Magic Doorgate Did you ever get an i-phone Stu :mrgreen: |
Re: Project: Magic Doorgate Nuts to yer iPhone :flipoff: Time to put some lipstick on this pig: http://i103.photobucket.com/albums/m...ps1euoufgp.jpg Put a sheet of 16-ga over the old bolt holes. Just bolted, not welded. http://i103.photobucket.com/albums/m...psdsdvrgau.jpg Put a nice deadly edge on the left-upper striker http://i103.photobucket.com/albums/m...ps7ctxalu3.jpg Installed the trim plate. Tacked at the corners, folded over on the left edge and tacked out of sight. This will get a coat of filler when it's warm enough for that. http://i103.photobucket.com/albums/m...pskwb7umds.jpg Mark it done! Although there's still some little things, like that dent still to take care of. Next challenge: http://i103.photobucket.com/albums/m...psvk3kiwff.jpg |
Re: Project: Magic Doorgate Moving on to the fuel cap. Ever since we bought the Challenger I've wanted to replace my boring fuel door with one from a Challenger. Fortunately they're all over ebay, so finding one cheap wasn't hard. The install could have gone a couple different ways. Way one would involve traipsing around a junkyard with a cordless saw. Way two involves beating on steel with a hammer. Way two seems faster and somehow more satisfying, so that's what I did. http://i103.photobucket.com/albums/m...psa34oyd2v.jpg Started with some 22-ga sheet steel with a hole cut in it. The hole is much smaller than the minor diameter of the tapered backside of the cap. http://i103.photobucket.com/albums/m...ps2smoh59v.jpg This is the back side of the cap, so you can see the taper. I cut off the part that I won't use. http://i103.photobucket.com/albums/m...psvzl8yutx.jpg Then I cut a hole in a board, tapered to match the cap (this is called a buck), screwed the steel to it, and beat on it for a while. http://i103.photobucket.com/albums/m...pstnvn5otj.jpg Bang bang bang bang. Start from the inside, slowly stretching the steel until... http://i103.photobucket.com/albums/m...psbzcmtyow.jpg ... it's flush with the surface of the buck. http://i103.photobucket.com/albums/m...psiau4nkwz.jpg The cap is retained by plastic clips, which need tabs to hold onto, so I made some of those, and primed both sides. http://i103.photobucket.com/albums/m...ps4l2sni8o.jpg In a rare instance of self-preservation, I used rivets instead of welding right next to the fuel filler, which just seemed like A Bad Idea. Alternatively, I could have lifted the bed off, which seems like Work. Not shown is the drain hole I drilled so the area behind the cap doesn't fill up with water or gas. It'll just dribble down the inside of the bedside. Photoshop: http://i103.photobucket.com/albums/m...ps9djes5dv.jpg This is what I'm going for, and close to. You can also see the rust over the wheel arch, which I've repaired twice and keeps coming back. So a big patch panel will go in there, and since I'll need to do filler and paint after that, might as well extend the work zone for a sporty fuel cap. For now it's in primer, which matches the primer all over the tailgate. http://i103.photobucket.com/albums/m...ps7j1xbbeq.jpg And yes, I can still put gas in it. I verified that yesterday. |
Re: Project: Magic Doorgate Hey Stu! |
Re: Project: Magic Doorgate Hey PeePee! Long time no see. Update! Another warm day today, almost warm enough to do filler and paint. So with a little assist from the propane heater in the shop, that's what I did: http://i103.photobucket.com/albums/m...pskwvgcsot.jpg Needs a good cure, wet sanding and compounding still (lots of overspray to get rid of), but we're getting there. |
Re: Project: Magic Doorgate Not too shabby there Stu, I bet it's alot easier on the back to get your stuff in and out now, nice work. |
Re: Project: Magic Doorgate Great job buddy , I like like how the hing's turned out. Also did you french the backup lights in the bumper? |
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Re: Project: Magic Doorgate I'm just glad you are alive |
Re: Project: Magic Doorgate Glad to see you still alive and,still being creative."thumbsup" |
Re: Project: Magic Doorgate Oh and what the hell... |
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Got another sort-of break in the weather (40F) and decided that was good enough. Good enough to cut and buff, anyway: http://www.scale4x4rc.org/forums/att...1&d=1453756323 Put on new pinstripes, painted the post again (had to install a drip guard to keep ice and snow out of the top hinge) and made a lower cap to neaten up the drip guard some: http://www.scale4x4rc.org/forums/att...1&d=1453756323 It ain't perfect, but it'll serve. Good enough to stick my name on it: http://www.scale4x4rc.org/forums/att...1&d=1453756323 Those are Stratus letters again. I just couldn't bring myself to use the chrome letters from GhettoZone. The primer on the right-hand fender will get done in the spring, since the bumper needs to come off and there's a little sanding to do back there. I'm kicking around the idea of putting a roll pan back on it, a steel one this time. Since I've got to break out the welder for the fender patch, why not. |
Re: Project: Magic Doorgate Sweet, when do we leave for scale nats? |
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Re: Project: Magic Doorgate Lol, only way is if he quit smoking those eye burning Winston's. :lmao: Cows be like...Moooo bitches! :lmao: |
Re: Project: Magic Doorgate Yeah Stu, where have you been hiding? :) |
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I got another couple of good weather days (notice that all the stuff I'm putting off til spring gets done when there's even a hint of warm weather?) so I put the new roll pan on: http://i103.photobucket.com/albums/m...psx0ryvoom.jpg It was a little tricky because the passenger side is 1/4 inch shorter than the driver's side (because I can't back up without hitting something) but I managed to get it in there, and the gate folds down without rubbing (much). I do have some adjustment on the right-side pin, so if I bump it up an RCH it should be out of the rub zone. http://i103.photobucket.com/albums/m...pswru825do.jpg Installed some big LED's for reverse lights. They're better for indicating than illuminating, but they do cast a (faint) blue glow on what's behind me. This may or may not be the final install. I'd like to get them flush, but there's not much room behind them. http://i103.photobucket.com/albums/m...pss3zoedfj.jpg The left side of the roll pan got a massage to clear the box-thing that covers up the slot I cut for the hinge. Paint isn't quite Johnny Bench perfect, but with a little wet sanding and a buff it will be. Also replaced the exhaust tips with some stainless quad Flowmaster tips. The big resonators stuck out even past the bumper, and almost 8 inches past the roll pan so they had to go. I like the quad tips better and they won't rust. |
Re: Project: Magic Doorgate Arizona this year. I like those tips a lot! |
Re: Project: Magic Doorgate Sweet, so I can add heatstroke to the total humiliation that's waiting for me there. |
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