Mounting "A" pillars and doors...

[JamesWilson]

After working all summer and fall on welding the chassis and inner body together I've now reached the critical point where I'm about to mount the "A" and "B" pillars and the doors. I've several days off from the office, and hope to work on it more-or-less full time for the next week or so and hope to finish by mid-January.

The plan:

1.) Mount the front shroud (Scuttle, front X panel, inner wheel arches and inner/intermediate sills already mounted).
2.) Mount the rear brackets (that attach to the "A" pillars) to the front wings.
3.) Mount the front wings.
4.) Position the "A" pillars and tack in place.
5.) Mount the doors.
6.) Position the outer sills.
7.) Check the door gaps and alignment.
8.) Attach the "B" pillars to the rear wings.
9.) Position the rear wings.
10.) Check the door gaps and alignment
11.) Tack the "B" Pillars in place.
12.) remove front & rear wings and outer sills.
13.) Weld "A" Pillar in place.
14.) Tack Reinforcing panel for "A" pillar in position
15.) Weld "B" Pillar in place.
16.) Re-fit Front wings and doors.
17.) Re-fit rear wings.
18.) Check gaps and alignment.
19.) Tack outer sills in place.
20.) Remove wings & doors.
21.) Weld reinforcing panel in place.
22.) Weld outer sills in place.
23.) Re-fit front wings and doors.
24.) Re-fit rear wings.
25.) Check gaps and alignment.

Any comments or advice would be gratefully received. /ubbthreads/images/graemlins/yesnod.gif

TIA

James

 

[terp83]

Hi James:

A longtime enthusiast/novice restorer has couple of questions regarding your checklist.

1.) Is your beginning reference point the front wings or the doors (or something else)? Stated another way, are you aligining the outer body components "back from the front wings" or "around the doors?" Your website (a great resource) seems to indicate that you are keeping the doors but replacing the wings. The doors are a known quantity, but would a slight variation in one or both replacement front wings distort the whole alignment?

2.)Do you intend to keep the doors mounted all the time between step #5 and step #20? The reason that I ask is your step #16 says that you are refitting them doors, which could mean reattaching them, or just loosening and retightening the hinge bolts.

3.)Is the rear shroud in place throughout this entire process? Its presence would provide still another visual cue as to panel alignment (especially on BJ series).

I will watch this thread and your website with interest in anticipation of resuming my dormant restoration of my 1965 BJ8 this coming year. My "A" pillars were/are in really good shape, and did not need replaced, even though most everything else (outriggers, sills, floors, "B" pillars)has been replaced. My big task will be getting the front "X" panel welded in just right.

Thanks for sharing your experiences with BCF, both in this thread and your outstanding website.

Jerry

 

[JamesWilson]

[ QUOTE ]

1.) Is your beginning reference point the front wings or the doors (or something else)? Stated another way, are you aligining the outer body components "back from the front wings" or "around the doors?" Your website (a great resource) seems to indicate that you are keeping the doors but replacing the wings. The doors are a known quantity, but would a slight variation in one or both replacement front wings distort the whole alignment?

[/ QUOTE ]

My prime reference is the Scuttle- the shround mounts to it and the chassis rail extensions- then the Front X panel and Front Inner Wings were positioned relative to the shroud, the chassis and the inner and intermediate sills- as with the old ones. The bonnet was used to ensure the shroud's curvature wasn't distorted.

My idea is to mount the front wings to the shroud to ensure that they match it well.

So my plan is to fit the wings to the shroud, and then match the doors to the wings, and then the rear wings to the doors. Basically starting at the front and working back. As the "A" pillars aren't mounted I cannot really start with the doors and work outwards. I've measurements from the disassembly and will use them as a check, but I cannot blindly follow them because the panels differ slightly. (not to mention the problem of the scuttle having been originally mounted a bit skewed)


[ QUOTE ]
2.)Do you intend to keep the doors mounted all the time between step #5 and step #20? The reason that I ask is your step #16 says that you are refitting them doors, which could mean reattaching them, or just loosening and retightening the hinge bolts.

[/ QUOTE ]

I should have said that I'd remove the doors in step 12- the idea was to get clear access to the pillars for their welding.

[ QUOTE ]
3.)Is the rear shroud in place throughout this entire process? Its presence would provide still another visual cue as to panel alignment (especially on BJ series).

[/ QUOTE ]

The rear shroud is loosely in position, and I'd keep it in place except for the "B" pillar welding. When I said I'd mount the rear wings I left unsaid that I'd do this with the rear shroud in place to ensure their proper alignment with it.

The rear shroud/inner wing/outer wing fit is making me thoroughly crazy and is one reason I've decided to work from the front backwards. The rear shroud fits to the outer wings without a problem, the shroud fits to the inner wings without a problem, the inner and outer wings fit to one another without a problem; but trying to fit them all together at once creates gaps and discrepancies. I can get any two of the three but not all- so the inner wings will be the ones that get massaged, if I have to. The rear shroud mounted at the boot floor and rear seat upright panel provides two reference points, and mounting the rear wings will give a rough idea of where the "B" pillars should go- and by starting at the front I should then be able to more accurately position the doors and get the rear positioning right too, and see whether I need to modify the rear inner wings so that all fits well. I don't anticipate having to reposition the rear shroud, and I try very, very hard not to consider that possibility....

 

[big6]

James,
The assembly of the three sub assembly sections that are welded to the frame start from the rear. You will need to begin with leveling the frame section on sturdy supports. Next set the rear section on the frame. Square the rear section to the frame and clamp in place. Measure from the forward side of the rear chassis cross member to the rear bulkhead 7 7/8 inches. The B posts are located at a 30 degree angle from the frame. I use tech screws to hold the rear section to the frame until welding. Install the rear shroud assembly and fenders. Next locate the scuttle on the frame temporarily holding it in place with locking pliers. Attach the doors to the scuttle section. With the doors closed measure 3/16 inch from the rear edge of the door to the rear fender mounted on the B post. Tech screw the scuttle in place until welding is completed. Next clamp on the front inner fenders and radiator support. Install the front shroud assembly and fenders. Move the front section allowing 3/16 inch gap for the front of the doors and fenders. Weld in place the front inner fenders and radiator support. Be sure before welding to locate the radiator and hood assembly making sure to allow for the radiator cap and hood.

The most important part is locating the rear section and squaring it to the frame.

Hope this helps.