23-SEP-2012
Closeup of the backing plate upper bracket
A closeup of the upper bracket ground the same as the lower bracket.
23-SEP-2012
Brackets welded
I welded a small weave pattern bead so that the weld would be pretty flush and not interfere with the closed door.
23-SEP-2012
Closeup of weld
A closeup of the flat weld I needed to lay down on the brackets. It's nice to have a project where I finally get to break out the TIG welder. Can't wait to start the roll cage.....
23-SEP-2012
Welded back side
Pulled all brackets off and welded the inside of all joints to make welds complete.
23-SEP-2012
Backing plate inside of door skin
This shows the 1/4" thick backing plate that is 2 5/8" wide by 6" long that will be drilled and tapped so that the new JK door hinges have a strong backing for support.
24-SEP-2012
Brackets complete
I picked up some hardware today and when I got home I countersunk all of the holes, shaped the corners and de-burred all the edges.
Now on to the task of making the mating hinges to match the JK hinges that are going to be bolted to these new brackets.
24-SEP-2012
Lower brackets complete
The lower brackets received the same treatment as the uppers.
25-SEP-2012
Laying out holes for JK hinges
Laying out the holes to drill and tap the new brackets behind the door skins. I'll use 3/8-24 bolts to attach the JK hinges to the doors.
28-SEP-2012
Making the female hinge
I had to turn down some round stock to get the diameter I need to make the hinge halfs that attach to the tub jamb.
30-SEP-2012
Opening up the center of each piece
After cutting each piece to the approximate length, I drilled a pilot hole then ran a 9/16" bit through each one. I will need to use a reamer and and sneak up on my final inside diameter to accommodate a snug fit for the bronze bushings that I'm using.
30-SEP-2012
Facing off
With the length of the bushing that I'm using, each piece needs to be the right length so here I'm facing off each piece to it's proper length.
30-SEP-2012
Each piece at the right length
Each piece was faced off to be exactly .990, they didn't really need to be exact but I don't get to use my little lathe very often so I figured I would make them as I designed them.