First job this week was to start manufacturing the emergency door window frame. On the Wednesday I delivered the the handle to the chrome platers at Ongar. Still waiting for the glass for the remaining O/S window. by the end of the week I had trial fitted the top outer frame piece to the ED window frame. This revealed that I needed to reduce the inner depth by 3.4mm towards the glass in order for it to fit properly against the inner surround, so I removed again ready for work on Monday. This also affects all the dimensions of the remaining outer pieces.
Tag Archives: Emergency door
28/720/24
Continued working on the emergency door, stripping off all the old aluminium cladding. It now fits, more or less and should be ok when the locking clamp is refitted which will pull in the bottom. The natural tendency for it to spring outwards is probably intentional so as to aid its opening. I found that many of the the joints on the door frame had loosened, so I reinforced these either by adding a new screw or drilling and gluing in a 6mm x 30mm dowel. I ordered the aluminium and the some 5mm dowels for the rebuild. Whilst waiting for these to arrive I created the template for the emergency door window frame and started to build it. I got as far as welding the first corner flange onto the base for the rubber by the end of work this week.
21/7/2024
Started the week by continuing to strip the emergency door. Firstly removing the beading, trying to save the half-round horizontal piece but that may not be usable. Next, the window frame – this is definitely not repairable and was well rotted, especially around the bottom. Next job was the removal of the locking mechanism for the door, then the plywood inside panel. This revealed the frame was in excellent condition and apart from a few holes to fill will need no work. Collected the first batch of seat cushions from Ifor on Wednesday, very pleased with them. Rehung the emergency door to investigate where it was sticking, it soon became clear that it was at the top; this required the removal of the internal wood cappings around the door aperture which in turn required the adjacent light fittings to be removed and they were quite stubborn. After doing this, I started to relieve the top of the door aperture and got it to the point where it will close properly without sticking. I turned my attention now to removing the corroded outer panel so I could see where it was catching at the bottom. Slow progress but forwards!