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Metal Fabrication and Repair Questions Ask all your Metal Fabrication and Repair Questions.

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Old 04-09-2017, 03:26 PM   #11
daves
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Originally Posted by mickleson View Post
The part of the conversion that I found concerning at the time was the need to hollow out the upper box inside the door and window frame in order for the new 2 door box pieces to fit.
I ended up cutting the 4 door tack strip retainer area and about half of the lower lip right off from about 6 inches in front of the roof brace back to about 3 inches approx. behind where the rear post used to be. This allows the new 2 door piece to literally plug the hole. I doubled it up over the upper part of the original box and made sure that all of the headliner holes matched up. Then I just started spot welding it back in.

I think it seemed like more work than it actually was, but I spent a lot of time figuring it out before I cut or welded anything. I think the other side will go much quicker. I decided to go with fixed rear windows even though I had the 2 door posts and inner panels. It just seemed like a lot more work to install some windows that will never be used. I may regret my decision down the road but I don't really think so. I have a 1960 2 door biscayne and I repaired the entire rear window systems on both sides and I don't think I've ever used them since.

I'm following you in this area and know the metal work for tackstrip needs to be extended down into the old door jamb top but I can't visualize what you did. Pics would really clear things up. I too am wondering what to do here.
Using fixed windows is the way I'll be going too. I had a 56 Belair two door post and those rear windows were never rolled down and I doubt functional windows will be missed here. It's that much less to do and the extra effort will be used in making this look right.
As far as the hours spent, I think Joe did good for spending 100 hours. Even though this has been done many times by a lot of guys, we're on our own and learning our way. There's no blueprint for us to follow and no instructions to read. If we just take our time I'm sure it will turn out fine.

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Old 04-18-2017, 03:05 PM   #12
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I've tried to load some pictures but haven't had any luck. You will find that when you go to lay the 2 door tack strip retainer over the original piece the back of the recessed area will hit the face of the original piece, and not allow it to sit in there properly. I first attempted to trim the bottom lip back but realized it was actually the top area that was causing the problem. The solution is to remove the entire bottom of the inner box area starting at the upper recess corner and just below the headliner bow holes. This will allow the 2 door piece to fit directly over the original upper structure that is left. I'll try again with the pictures.

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Old 04-19-2017, 08:00 PM   #13
joe cool
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I had no desire to make the back windows function. I will just use some metal tabs and set it all in RTV .I hope the front ( door) windows will use the four door front window mechanisms, time will tell.I am tempted the eliminate the front vent windows but probably won't. drilling out spotwelds in the rockers now ,way less fun than it sounds like.
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