Well today was a frustrating day. One of those days when I question myself wither it's all worth it. I wasn't even going to log it because I wasted at least 4 hours of torment. Bottom line it's an education so I press on.
My torment was the passenger side door rear flange. The .032 "L" bend pilots side was easy enough but the passenger side is .040 and has a "J" bend. It seems like it should be easy enough but this is one of the most challenging pieces I had to make. I bought a 6' length of .040 just for this piece but I soon figured out that I was going to have to make it in 2 parts. The issue was getting the "J" bent into it. An 8' brake would have made it and easy task but since I don't have one I had to form with a dead blow hammer. I tried using the 36" brake but it was no use.
I attempted to make the part twice but scraped both. The second one was actually working out but the channel had a bow in it for some reason and as I tried to heat and correct it only produced more issue. The trick is going to figure out what method is going to work best to make the bends.
One other issue I discoverd was it looks to me that there should be a flange at the top of the door frame. The rear vertical flange does not align with the top tube that the window hinges on. The window frame edges when closed would not sit flat. I see Eric has a flange there however it isn’t discussed in the manual. The kits do not have a flange. I asked the group but got no feedback.
