Old Rusty is back, more welding and bending

[Music] hi folks and welcome back to my channel and this is another video of volt rusty and yes I know it's been a while but I've been so busy with other projects but now I have time again for rusty so we're going to fix this door because that door is in a very bad shape we've done the left-hand door already now we need to do the right-hand door one of the issues with that door is that it's so far gone that it's going to be a lot of work actually to repair it so I might find another solution and you might remember that we picked up a couple of doors in France last year and this is one of them so this might be the one that we're going to use as the donor door for rusty however the hinges are a bit different and there's a couple of other things wrong with this door at the bottom side is gone as well but not as bad as the old door on old rusty so what we're going to do in this video is to remove first of all the old door and then match up the hinges and see if we can fit this replacement door and then actually fix this replacement door because even that one is bad so the first thing we're going to do is take the door off and then match it up with the second door but the hard part is to get these bolts out of this frame they are so rusted and they've been in there so long so it's going to take a bit of effort and there are many different ways of doing it one more destructive than the other one that's where they are you see that and it's not even a cross or a hexagon it's just a slotted screw so the screwdriver will slip out very quickly so we have to find a way to get those out removing old screws aren't a russet vehicle can be very tough now there's a couple of methods that will help you and I'm using D wd-40 as a spray to release the screws as much as possible but that often doesn't work on they're really rusted screw but it helps for sure the alternative is that you use an impact screwdriver certainly put it on the nut or the bolt or whatever it is or the screw and you hit it with a hammer in the back and then you hope you can get it done but as you can see the screws that we have here are slotted screw so that's going to be a bit tough the other way you could use a impact hammer right dramatic one that's what I have here very good so I put a bit up there which is a slop bit so I can put it in in the screw and then try and get it out that works sometimes but not always another way of doing it is actually to use a little blowtorch and actually heat up the screw you know as much as you can and then use any of the other tools to release the screw that typically works well so I'm gonna heat him up and then try it and I'll show you a few methods but I'm afraid I will have to revert back to more drastic matters which is actually drilling out the screws with a special bit now if you're gonna drill out screws you may want to use a reverse bit and this is a reverse bit so you can use the reverse bit to drill the screw out and because it's a reverse bit it may actually take out the screw properly while you're getting deeper into it if that doesn't work either then you could just drill a hole and then use the reverse tap that's another method but I have bad experiences with taps because they've been broken off a couple of times so my options really are heated up try the impact our hammer and if that doesn't work I'm gonna drill it out and tap note rat in it or even have to put an insert in so let's get all and let's start I'm going to start with heating it up and then use the impact screwdriver and see if that is going to work or not so let's heat it up and then we try the impact screwdriver there we go that keeps slipping I'm going to try to put a deep groove into the screw where the Dremel and a small so now let's heat it up again and see what happens very handy torch for this kind of purpose it's a butane oxygen type of torch there we go you've seen on how I actually removed the screws quite easily with an impact screwdriver and some heat that always works that's a great combination of course you've got to watch out that you have no trim inside that can caught fire or electrical wires and stuff either but the small blowtorch like this one is very handy for this kind of work you may have to cut a deeper groove in it or if the groove is worn out already then you might have to cut it a bit deeper so you have a better bite but your impact screwdriver for that a dremel where there small disk is very handy so now let me do the top one and then we'll take the door off and as expect that one didn't want it to play so now we will go and drill it out sometimes hard to get too bit going to it so that's where I'm going to use an apple and this is an apple that wasn't clean it up a bit so that should be it so now we should be able to get it out and here it is almost there we go this is the piece we got it out and now we can remove the door so I have the screws to move from the inches one was a bit tough I had to drill it out the restaurant quite smoothly so now let's take off the door I'm holding it in place a bit but this dream will here so it comes fall let's see how easy that is going to be and that is not gonna be that easy as you can tell it is probably all rusted into place [Music] let's see help us yep you know here we go the next thing we're going to do is trial fit this replacement door and let's see how that works it has quite a bit of damage on this site so we'll have a bit of work there but it's not too bad so let's move it up and see if we can get it in I'm a bit lazy guys so I'm using this engine lift because these doors are a bit heavy and I'm a bit of an old mind so let's try to move it in a bit I just want to make sure that this door fits before I do any work on this I think of course can always try to place them on top of each other but I think this way is the better way to do it that looks like it's going to be today all right so I think this is going to be a good fit the door fits nicely all around there's going to be a little bit of work on the store especially at the handle area it's really been bent and dented so that we'll have to fix but all along I think this is matching up not too bad and again it's a bit loose I have a bit more opening on the bottom but okay the door is not fully in yet the next thing I'm going to do is to take the door back off the truck and then start working on this door the door has a problem with the handle here well we need to fix that it's really dented in but it also has issues with the hinges the hinges over here are kind of welded on and there are a different type of the ones that are on the original door so I have to make that the same thicker of the old door put it on this one and the bottom of this door is having some other issues let me show you down this is the bottom part of the replacement door and as you can tell it is rusted away so I'm gonna clean it up a little bit so I see more what we have so then we can decide on how we going to fix this so the way we're going to fix this is by actually cutting this part off here well my pen doesn't work too well like so and then here this piece is alright so I'm just going to leave that as is and then I'm gonna try this edge to bend it open a bit and then we make a panel that will go along here and slide under there and then we weld it in place so this is a bit what we're going to try to do here it isn't that much work I don't know how easy it will be to bend this open this edge but we'll see so first I'm going to start by cutting off the old metal and then we have a better view of where we are I've cut off the side here the rot of metal and now I'm going to clean this up a bit to see where the spot welds are so I can actually try to remove that metal part that sits underneath this lip here so that's the next thing we're going to do I see all kind of stuff sitting here I don't know what that is funny those sanding wheels with abrasive paper and multiple layers are really really handy 2d rust or to remove paint from a vehicle or another piece of metal it they really work well they are not cheap but they are really good so let's put one up and then we'll see how that goes I'm gonna put my mask and the goggles up because those nasty the next thing I'm going to do is to look on the lip for potential spot welds areas but you have to look very carefully this is one right here and I'm just gonna go along the whole edge and try to find them I'm sure there will be more but sometimes they're a bit hard to find so these spot-welds be going to drill out now so drilling out the spot welds isn't all that difficult and that looks quite good so now let's see if we can actually climb it off it's bit tough still no it's gonna work removing drilling out the spot welds was an initial thought but things are so rusted even underneath that it's going to be very hard to do that and I'm going to damage the edge way too much so I'm gonna do it differently I'm going to cut the edges off here all the rusty part and then I'm going to try afterwards to get on the need with a dremel and you remove all the material which is underneath [Music] it's kind of funny while I was removing this metal here I found pieces in there think this guy must have been a plumber or something like that it's an old ruler and I think there's even it's another one in there that's a bit more stuck in it there we go well that broke guy I wonder if there's more of those funny things inside okay right so I'm going to use a dremel now to cut underneath this lip and the only problem is I need to get them in first now long as I got it in there we go or I can start cutting [Music] we're going to start to clean up the inside and we blast it a bit bit the sandblaster you know the ruler in there and that must be the glazing as well oh that stuff must have falling down at the time all right let's get it all out it's amazing isn't it is even kind of a newspaper in here I wonder from what year that is oh now I broke it and I can't see the year maybe I can find out anyhow all this junk came out of it what a collection so now I'm going to paint the inside with aluminum zinc spray so it's protected but I'm going to tape off of course the area where I'm gonna be welding because I don't want to have paint in that area because otherwise we have to grind it off again and I don't want to do that alright let's paint that done know about you guys but I'm getting pretty hungry so I'm gonna have my lunch and then we continue with this work so this is a here we got the template and that just fits fine that's how we will fit it and I already have cut out the metal piece according to the template and now we're going to bend it along the white line so we can actually fit it so we're going to bend it and that should go quite smoothly I know it's not a 90 degree Bend it's a bit less so let's check it out how far we are with this oh it's probably needs a little bit more that should be about it I need to trim it a little bit I made it a little bit too wide so see that even happens to me guys but then we just cut it off and get it all sorted out so I'm using some small clamps to hold the panel in place and they are quite handy I think I got them for like 2 euros apiece so now we are about ready and we're gonna start welding it on the top but before doing so I'm going to grind it a bit more down so I have good solid bare metal for the welding [Music] [Music] [Music] so these clamps are extremely handy [Music] so we finished up all the welding and now it's time to clean it up I didn't do a complete seam that's not necessary it's spot welded in different areas so now I'm going to clean it up and then we start working on the hinges so this is all finished and now I'm going to drill two holes for draining the water just in case we would get water in sight so folks so far we have taken a door off old rusty we checked at the new door or the replacement door is fitting properly we fixed the bottom side to drill some holes in it we patched it up now it's time to look on the hinges and on the door handle because that takes a bit of work as well so that we will flip it over that is a frame that will go around the rubbers once you put the glazing in so I'm going to put that aside I'm happy to have that one because I'm missing that part on the other doors so it looks like somebody welded on these hinges who are at least out a part of it so we need to get this off all right that's one piece so I got the hinges out the same way as we did it on hold rusty by heating it up and I think there's still a little bit hot and let's see yep they are hot so let's see if we can get it out now I think it's still welded on a bit so we need to grind it off that's out so now we need to clean up this whole area so we can fit the hinges from the old door since I had to drill out some of the bolts on old rusty for the hinges and these are the hinges of old rusty I will have to retype the holes and in fact I don't even have the original bolts so I'm going to use em eights so I have to drill them out and now it a tap put new tread on it so I got to do about twelve of those holes [Music] we drilled out the holes and now it's time to put new tread in the holes and I'm going to use an m8 tap for that I'm gonna come back sometimes a bit but this is a brand new tab so this should be working just fine we drilled the holes in the hinges we then put new tread up so now I can fit in m8 but an m8 is having a pretty big head and the head is a lot thicker than the original bolt that I have over here so because the balls are opposite to each other when the hinge is closing you know this is becoming real thick so I may have to turn off a bit on the heads of those bolts on the late but that we'll see later so right now or let's try to fit him nothing that looks quite good guys so uh done so now let's have a look on the handle the next thing we're going to try to fix is the door handle you see how this is bent in so either I remove this one and I use the other one from both rusty from the old door or we can fix this one I'm not sure so let's see if we can get it off the same sides willing there we go alright so now I should be able to remove the inner part but for that I probably need to undo a bolt on the side here I don't know if you can see it but this is the one that has to go out and I'm afraid it's gonna be another one of those tight ones is another one right here so we need to clean that up of it and I might want to heat it up let's try no it works if I don't need to heat it up I won't you know that one is easy but that's because people put oil on the locks right so now that whole thing hopefully can't come out unless there's another bolt or screw somewhere finally I got the hinge out however now we need to straighten up this whole area because it was really really badly bent so I'm going to try to do this with a piece of metal and a torch and maybe with an old screwdriver we will be able to lift it a bit so let's see if we can do a bit more I'll heat it up when I give some light pressure right so now let's do the other side I've been hammering this area we've been beating it but there are some pieces that are broken so now we're going to weld those up first of all soft well we also need to do the other side there we go and this is all about squeezing and pushing guys nothing more in the metal bar Pollock helps so let's see on that fits all right I think this starts to look alright see that looks already a lot better doesn't it I think that looks quite good compared to what I was before okay now of course I don't have to look at the inside but this looks good so let's put the door back up it's been a long day guys but finally we've got the hinges back we've got the door handles sorted out and there's a lot more work to be done on this door in fact also the other door the winding mechanism for the windows all that kind of stuff still needs to be done but that's going to be for another video because we can't do it all in one video because that would be too much you now there we go I've got the bolts and not all of them just a few so the door is holding so let's relieve this and then see if we can actually close the door now [Music] the door is fitted and it looks a reasonable or right however sees pinching on this side here as you can say so the door fits a reasonable well however as you can tell the door is actually very close to the side here and in the back I have about a centimeter so I will need to sort that out the horizontal line is quite all right it fits on the top as well so what I will need to do is to put up some washers on the hinges at the inside so it pushes that door more backward at the same thing I'll do over there but that's just a matter of putting washes in and at the same time the door has to come out a bit and that's why I need to cut in the chassis where the hinges are connected some slanted slots so I can slide it out a little bit not much it's it's actually only this side here which needs to come out just a bit and then we should be okay because here it feels kind of all right over here I see as well it's leaning outward a bit but I think if the door is gonna tip like this it's just gonna fit nicely so guys I'm not gonna bother you with showing on how to put all the Washington Space Center because this is a lot of fiddling it's just putting a washer or a little metal plate you know tighten it up again have a look how the gap is and back and forth until you it's weird it's supposed to be so I think it turned out quite alright the door is nicely repaired on the bottom now the door is solid I took the whole Mack in his mouth because I have to recondition that and you'll see that in another video and the bolts are actually not touching each other so I don't need to grind them down on the late or something like that and because they are kind of offset so these bolts are in an offset compared to the bolts in the door so that's a good thing so folks this is it for this video I hope you enjoyed it and more videos are to come the next video will be all about sandblasting the cabin because that's the first thing I need to do now before I start putting lead or any other kind of polyester fillings up I think I'm going to use that but you never know so I'm gonna sandblast the whole cabin so that's gonna be the next video coming out that might take about a week or so because I still have to get the sandblast and reserve it and get all the blasting signed and then we'll see how that goes so I hope you enjoyed it guys and I'll see you in my next video bye bye

Channel: D3Sshooter

Views: 19,918

Rating: 4.8965516 out of 5

Keywords: old, rusty, citroen, u23, truck, restauration, timer, classic, bodywork, doors, parts, how to, do it yourself, welding, mig, cutting, hbm, hinges, handle, rebuilding, wwii, rust, corrosion, WD40, sheet, metal, rusted bolds, how to remove, torch

Id: rBdUpSyrGrw

Length: 35min 12sec (2112 seconds)

Published: Tue Aug 13 2019