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turbo355Offline
Post subject: Aluminum Doors (Updated with more pictures dialup beware)!!!  PostPosted: Sep 09, 2008 - 05:25 PM
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My car has been setting for around 2 years now waiting for me to get the energy to tackle replacing the doors, they are around 12 years old now and are really starting to show their age, i have a brand new set of fiberglass doors for it but i decided if im going to be messing with the doors, why not start from scratch.

This was my car before i started on the pass. door .





The doors have always leaked around the tops,, and i could never keep the side glass from breaking eventually, since the top frame was so weak . So i started with a sheet of .063 aluminum , and started building, i have about 20 hours in this door so far including the window regulator stuff, witch still need some work but it seems to be going good so far. ( please forgive the bad pics i will shoot some better pics )








The window regulator is out of a 95 (or so) Ford escort it is cable drive setup ( real simple and free ) So i started and made a stell bracket out of 3/16 plate and turned out some pully wheels for the cable to ride on i also made up a bracket for the window to set in out of .090 aluminum that the cables also hook to this will be urathaned to the window to push and pull the window up and down in the track , i made an adjustable to take the slack out of the cables for adjustment .








As you can see i put the window bracket at the front of the window as this seemed to work the best for working the window, if it was to far back it would pull the window out of the channel here it seems to work real good.





Here is a shot from the front, i wanted to stay as close to the orignal design for the doors , so all the window channels are welded to the door itsself , and the wing glass divider bar has the inside support just like the real countach, this helps to hold the corner of the top of the door down on the seal without any movement .





And here is the front of the door where the wing glass slides up into this will have felt strip inside so once the wing glass is slid into the pocket it will be sealed from the outside.






Thats all for now i will take some pics of the inside of the door when i pull it off the car , i still need to add a window bracket to the back of the glass with a cable going to the front to make sure the back cant slide up out of the channel once that is done then i can skin the door and start on the drivers side.

I know it looks like alot of work to buld a door out of aluminum but i just dont like the fiberglass doors for these cars ( or atleast the ones i have) i weld aluminum almost everyday here at the shop so it seemed like a good project and so far im happy with the outcome we will see once i start to skin it if i still think it was a good idea. LOL

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car pic here--->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103


Last edited by turbo355 on Dec 17, 2009 - 08:32 AM; edited 1 time in total
 
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AdrianBurtonOffline
Post subject: RE: Aluminum Doors  PostPosted: Sep 09, 2008 - 05:48 PM
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MAN THAT IS B E A U T I F U L ! ! ! ! ! ! ! ! ! !

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turbo355Offline
Post subject: RE: Aluminum Doors  PostPosted: Sep 09, 2008 - 05:53 PM
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Thanks it still needs alot of finishing work before i call it done but so far it seems to fit pretty good.

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turbo355Offline
Post subject: RE: Aluminum Doors  PostPosted: Sep 09, 2008 - 05:55 PM
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double post.

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rodrieguzOffline
Post subject:   PostPosted: Sep 09, 2008 - 06:40 PM
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That is some nice metal work there, Wink

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What makes a Dream a reality....YOU!

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RTOffline
Post subject:   PostPosted: Sep 09, 2008 - 08:23 PM
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WOW!
Nice work.

RT

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Pantera/DiabloOffline
Post subject:   PostPosted: Sep 09, 2008 - 11:57 PM
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SUPER NICE METAL WORK!
 
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guywithlamboOffline
Post subject:   PostPosted: Sep 10, 2008 - 12:37 AM
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nice, you'll be the first one to have working side glass on Countach
 
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gwaderOffline
Post subject:   PostPosted: Sep 10, 2008 - 01:12 AM
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WOW!!!!!!!! That red is bitch'n.

greg

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turbo355Offline
Post subject:   PostPosted: Sep 10, 2008 - 01:21 AM
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Thanks guys .

These wont be the first countach replica doors that the windows work in as there have been quite a few done before .

I didnt work it tonight but i will be back on it tomorrow for sure so i should have some more pics up to show the inside of the door and hopefully by the weekend it will have a skin on it.

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AdrianBurtonOffline
Post subject:   PostPosted: Sep 10, 2008 - 11:52 AM
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Turbo

You have to detail everystep of that build on those doors. I gotta see it

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turbo355Offline
Post subject:   PostPosted: Sep 10, 2008 - 06:31 PM
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I sure will i still have the drivers side door to do yet so once i start on it i will document the whole process for anyone who might want to try it thier selves.

I am redoing alot of the car so i will be here for a while .LOL

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turbo355Offline
Post subject:   PostPosted: Sep 12, 2008 - 08:10 AM
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As promised here are some shots of the inside of the door, it still needs alof of finish work, but the over all shape, and fit is correct so far. Also note the inner door frame itself, is seperate from the outside of the door frame, so basicaly its like having a frame .128 thick, but since its two pieces, and it has 90 degree bends in it, it is stronger than a single piece.















Here is a shot of the inside wing glass support bar this runs from the top of the door frame to the 1x1 bar at the bottom it is made out of .080 thick sheet bent into a u section then welded the whole lenght of the window channel





Here is some shots of the pulley wheel setup im using , the front has 4 wheels, 2 are for the actual drive setup, and the other two are for the back of the glass, a cable runs fron the front glass tab to the back of the glass through 2 more pulleys, this keeps the glass from sliding out of the track in the back plus helps to pull the glass down . Im still unsure if this is the final setup i will be using so untill i know for sure i will wait till i do the drivers door to show the cables in place.










Here is the start of the skin, the top has returns for both the front wing glass, and the back lower glass, so felting goes on, then the glass can be installed ,and a final trim piece will go on just like the original doors, this should make for a water tight seal to the windows from the outside ( hopefully) . I still have more welding to do to the top skin, then i have to file and sand it all down, then i can start on the main side skin and scoop.






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Lambo2005Offline
Post subject:   PostPosted: Sep 12, 2008 - 11:10 AM
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That is aewsome looking.. good work!
I always felt the countach design looked a bit dated but with the wheels and tires you have on that I really like it a lot.. Nice looking car..

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Flying_RoadsterOffline
Post subject:   PostPosted: Sep 13, 2008 - 03:08 AM
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Great job man. Lines are perfect, you can really be proud of those.

GW

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