Project Pile House- Shaving the Door handles
In this video Matt goes over some tips on shaving a door handle. Get Metal Fab Tools: niceloveme.com?utm_source=youtubeLIVE&. In this video Matt goes over how to metal finish a door after welding in a patch. Get Metal Fab Tools: niceloveme.com?utm_sou.
One of these is to address removing the factory door handles. Since guys have been customizing cars, shaving the door handles has been one of the most common modifications to make the car look as smooth as possible.
This process can be a pretty simple process, but there are a few things that can make it go smoothly. I decided to show the process on Project Pile House. I decided to shave the handles, but make a cut-out that you could pop the door by a button inside the door jam.
Once the fabrication for the door latch was done I had to shave the holes from the door handles. In this case the body panel had a stamped, raised portion around where the handle mounted how to fix a broken zipper on a coat I needed to cut out around what makes a good cv cover letter replace.
This meant that I had to make a patch panel that matched the curvature of the door in that location. I started by putting a piece of cardboard behind the area I removed and tracing the opening. I then carefully cut out the cardboard piece until it was how to shave your door handles tight fit in the opening. I made a little loop out of painters tape to use as a handle to test fit each time. I avoided using a sharpie marker here as I wanted as exact of a tracing as possible. Because this patch panel needed to have a curve to it I traced the patch more to the center of this large panel.
This was so I could have room to hold the panel while I formed it in the English Wheel. I only wanted a mild curve to the panel, so too heavy of pressure would have formed the panel too much. Once I had the shape of the patch panel transferred onto the metal and a curve rolled into it, I used the Throatless Shear to rough cut the shape out. I wanted a tight fitting patch panel, but too tight could cause the panel to have a high spot when you weld it together. I solved this by carefully using a half round metal file to take small amounts of metal away exactly where I needed to allow the patch to fit perfectly in the opening.
I was planning to TIG weld this joint so I wanted as little of a gap as possible. Using panel clamps I held the patch in place and put small tacks around the panel adjusting the panel as I went to assure it was aligned and flush with the existing panel.
I then slowly worked around the panel laying short, quick welds with the TIGthe mini WP-9 torch. As I welded the weld seam started to sink all welds pull in towards themselves and I began hammering on-dolly to stretch the weld seam back out while it was still hot.
I like doing this hot for two reasons; the weld is softer and you can planish the weld flat with the panel and the metal moves easier when hot allowing you to reverse the shrinkage more easily.
While you could weld how to shave your door handles panel completely, then hammer the welds afterwards, it takes a little more work and skill to fix the warpage evenly.
I find working a little at a time controlling the shape of the panel is easier for me. Once the panel was welded and the majority of the warping was reversed, I used the pneumatic angle grinder with a 36 grit sanding disc to knock any proud welds down.
Once the welds are knocked down I lightly hit the entire work area to how to fully erase a hard drive it all the same texture.
I then start using my hand to feel the panel for any low spots and use the reflections on the panel to read where there are low spots in the panel. I then use the appropriate hammer and dolly to match the curvature of the panel to raise the low spots.
I used the bullseye pick to raise these spots and check my progress with the medium cut slapping file. The nice thing about the bullseye pick was that the body was slim enough to allow me to fit the tip into the inner door opening with the window and regulator removed and work the metal where I could never swing a hammer. With one side down we can see it really cleaned up the side of the truck with the subtle cutout in the door giving a little hint to the custom work done to the door.
The next step will be tackling the process of removing the ugly upper door hinge and dialing in the gaps on the door. I will be showing that process on the other side as this side took a bit of figuring to get it working how I wanted. Thanks for following along! Would fish plating reduce the amount of shrinkage?
I then welded the access panel back in place once I was finished with the job. Matt good timing on this demo as I will be shaving my door handles soon. If not Tig but Mig welding the patch panel how much space do you reccomend around the patch. I assume you will be using door poppers if so your imput to that process would be really helpful. Ive shave door handles on a ranger truck, had warpage with a mig, even though ive done alot of auto metal work over the yrs, even with small welds and letting it cool.
One thing that is a common misconception is that pretty much all welds on sheet metal will pull or shrink in around the weld. This is just the nature of the beast due to the heat involved in welding. TIG is used to keep the heat effected zone down, produces smaller, flatter, welds, and gives you more control over the weld puddle. Another positive is that the welds are softer which allows them to be hammered and dollied and they require less heat to sand down. The length of the weld all depends on the project and personal preference.
It also depends on your metal bumping skills as some high end guys weld a panel completely in one pass and hammer the weld afterwards, while I prefer to go only inches at a time and then hammer the weld flat and stretch the metal back out as I go to keep the panel in shape.
The panel gap really depends on your welder setup. I always practice and set my MIG up on a scrap piece of metal or test panels to assure I am happy with how well the welds penetrate and look. I like the hinge look JMO shaved how to evolve riolu on pokemon indigo are cool but the hinge shows you its not a kit car….
You can then make a a pattern and transfer it to sheet metal for your filler panel to fill the space in the center. You may need to roll the filler panel in an english wheel to give it the same shape as the existing fender. If you make the filler panel a little larger than you need you can lay it over top of both halves of the fender and slowly tack weld it in place to hold the shape you need.
You can then use a thin cut off wheel to cut the excess off on each side and then pull the filler panel flush the existing metal and tack welding. Do this process jumping around until you have the entire panel trimmed and sitting flush with the existing metal.
Then slowly weld the seams up, stopping to hammer each set of welds flat to control the heat warpage. Any update on the other side and the products used for your shaved handles? Have I missed it?! Stay tuned thanks for watching! You must be logged in to post a comment. Top Selling Products. Keep these coming! Thanks Joe, I will be showing that process on the other side as this side took a bit of figuring to get it working how I wanted. Hi Don, One thing that is a common misconception is that pretty much all welds on sheet metal will pull or shrink in around the weld.
Hi Jim, The panel gap really depends on your welder setup. Any suggestions Pat. Gene Winfield would just sculpt it with lead and make it pretty. Nice joband thanks for the write-up. Thanks, Stan R. Leave a Reply Cancel reply You must be logged in to post a comment. Hosting a Car Show? Email Deals Sign up now to receive exclusive email deals, industry news, and new product releases. Connect With Us.
All rights reserved.
Introduction: Shaved Door Handles ...... the Cheap Way
niceloveme.com to shave door handles on a 93 chevy truck. Jan 24, · Quick video of how to shave door handle this is on a Plymouth Arrow truck. Jul 30, · I decided to shave the handles, but make a cut-out that you could pop the door by a button inside the door jam. Once the fabrication for the door latch was done I had to shave the holes from the door handles. In this case the body panel had a stamped, raised portion around where the handle mounted that I needed to cut out around and replace.
OK lets get started first you need to remove your inside door panel depending on make and model of the vehicle it may be held on by screws or clips mine was held on by clips be sure to save the door clips or screw other wise you will be hot gluing it back on I just used an existing power wire for my amp next mount your internal switch..
OK so now take your actuator and place it in side the door in the very bottom under the lock clasp mark the location of the screw holes in the actuator on the inside and out side of door by sliding your metal punch threw the screw holes and and giving it a love tap now with your drill drill out the holes and connect your wires Reply 3 years ago.
Reply 12 years ago on Introduction. He's now got a hidden button that opens his door It's just damn cool. But if you really just need justification, It makes it so he can open the door with his foot while he's carrying groceries for the wife. Reply 11 years ago on Introduction. Very good advice, I use a 4 way only need 2 trailer plug for outside power, as my HHR battery died no way to open the car, was able to google hood latch and made a rod to open my hood, you can jump your car there, hence the plug looks like a common trailer plug no problem.
The dyi wasn't that bad just a few tweeks, no a days you have remotes and on my HHR I just hooked my power door to the lock, I would never remove the inside handles though. This remote means you don't need a switch where people can open your ride. Removing inside door handles does not sound too smart.
Hate to have to get out of that cab in a panic And filling a deep hole with bondo is something that nobody with ANY common sense would ever do. Or it will eventually crack and fall out, especially as much as U put on there and the fact that the doors are always opening and closing. Anyone with any common sense that wants shaved door handles Should run as far away from this diy as possible. Worst diy write up I have ever seen Punctuation and spelling are important when U r trying to explain things to people in detail.
Not to mention the way U have done it leaves many Opportunities for failures and really makes it easy to break in to your "truck". Reply 6 years ago. I have to agree with everyone else: that bondo isn't going to last. These meets neither of these criteria. Please let us know how long it lasts, but my money isn't on that being very long.
One alternative to actually doing the proper metalworking, which is easy, but still a pain if you don't enjoy bodywork, is to take some steel and rough out the contour. Weld or braze it in, then apply bondo or lead, and sand until it matches. It's much less likely to crack or fall off that way. Reply 7 years ago on Introduction. As a professional custom body shop owner, I had to leave my comment.
This is a good instructional for those trying to cut corners and save some cash. When I shave door handles, I always hook the trigger to an auxiliary outlet in an existing alarm system so the remote can be used to open the doors.
The lil "poppers" that help open the door are just enough to get them to the point that you simply open the door by holding the edge of the door at the door jamb. As far as the hole in the door. The ONLY way to have it last is to weld a piece of sheet metal that conforms to the original shape in place. Grind the welds smooth and a light coat of body filler will finish the job. Sometimes, as in this case, to do it right is easier and faster than to do it wrong. But all in all, this instructional will help a lotta people get the job done.
I also have used trunk actuators do make the doors open. This works for most modern cars with easily opening doors. Older cars might need stronger actuators. Somewhere in the 45lbs range. Trunk actuators push about 11 lbs. Introduction: Shaved Door Handles Did you make this project? Share it with us! I Made It! Giant Saw Blade Table! Reply Upvote. They also sell emergency popper kits in case your battery does go dead. Why do you want to not have door handles?
How do you open the door now? BossTom shammallamaman Reply 3 years ago. BossTom greggspen Reply 3 years ago. BossTom abstracted Reply 3 years ago. My handles are already shaved, but my 2 front doors are jammed. How can I get them unjammed? BossTom ladyswan77 Reply 3 years ago. JerryM28 5 years ago.
Rishnai 12 years ago on Step 7.
<- How to set a wedding table - What is 27cm in shoe size->