Blowin' the doors off....

Well was a short day today working on the Tomato. The tasks of the day were getting the holes pulled for the door power feed harnesses and get the doors removes. When I purchased the power window assemblies from Jeff Munn, I had him to also send the the leading edges of both doors so I could locate everything as shipped from the factory. This also allowed me to know the exact sizes of the holes I needed to put in the doors and hinge posts so the harness bellows would seal correctly. The factory openings measured roughly 1 7/8" in diameter and I knew that would be a tough job cutting those with a hole saw so I checked at work and found the Greenlee punch for 1 1/2" conduit was 1 15/16"... close enough.

I used my step drill to cut the 1/2" pilot hole for the draw stud and with the help of my buddy Jim maneuvering the punch into position to clear the side impact bar in the door, it was a simple matter of pumping the hydraulics to pull the punch thru the thin material of the door skin and voila.... nice smoothly cut round holes in the leading edge of the doors in less than an hour......

Next step was to remove the doors so we could access the necessary location on the hinge post of the body to pull the opening cabin of the car....







With the harness holes in place we laid the first door on the sawhorses so I could begin the task of cleaning, prepping and painting the insides of the doors as well as getting the interior side prepped for paint.....

Until next time...........

ZEBRA 3 OUT