\nFigure 1 shows a rusty stop adjacent two strips of metal ready to be formed. The original stops had small edge flanges to add a bit of rigidity. Figure 2 illustrates forming a flange on the straight section while Figure 3 shows a piece of lumber routed to form a sort of die to form the flanges on the curved sections.<\/p>\n
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<\/a>1. Cutting Metal for New Door Seal Stops<\/p><\/div>\n
<\/a>2. Forming Metal for New Door Seal Stops<\/p><\/div>\n
<\/a>3. Wood Die for Forming Door Stop Edges<\/p><\/div>\n
Finishing the New Door Seal Stops<\/strong> 4. Flattening Door Seal Stop Mounting Flange<\/p><\/div>\n 5. New Door Seal Stops<\/p><\/div>\n 6. Painting Back Side of Door Seal Stops<\/p><\/div>\n Welding the Door Seal Stops<\/strong><\/p>\n Even if I had a spot welder, it would be almost impossible to spot weld these. Therefore, holes are drilled for plug welding, and the body was primed in the non-weld areas as shown in Figures 7-9.<\/p>\n 7. Holes Drilled for Plug Welding New Stops<\/p><\/div>\n 8. Priming Metal Between Weld Points<\/p><\/div>\n 9. Priming Metal Between Weld Points<\/p><\/div>\n The End Result<\/strong>
\nFigure 4 shows a pneumatic die being used to flatten the mounting flange. Figure 5 shows the completed stops. Note that the mounting flange is modified a bit below the large curve where it meets the frame, scuff plate, rocker panel or whatever you call it. The back sides are painted as shown in Figure 6 because the backs are almost inaccessible after installation.<\/p>\n<\/a><\/a><\/a><\/a><\/a><\/a>
\nFigures 10-12 show the installed stops and one plug weld side. Not an exact duplicate of the original but I don’t think anybody will notice, and they are better than the original.<\/p>\n