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 Once the skin fits they way...  Once the skin fits they way they want it, Walden adds the door’s reveal using his Pullmax machine. Once one side of the reveal is stamped, the die is turned 180 degrees so the other side can be added.  Here’s the panel with the...  Here’s the panel with the body line added, but not yet secured to the structure as the window opening needs to be added.  Kent and Walden work on matching...  Kent and Walden work on matching up the doorskin to the window opening, using screwdrivers to pry the skin out and to the proper curve. Once they agree on the shape, Kent scribes a line along the base of the window opening onto the doorskin.  After another test-fit, a...  After another test-fit, a slight correction is needed, so Walden uses a nearby wheel to fine-tune the panel’s shape.  Excess metal is removed, and...  Excess metal is removed, and Kent tacks the top piece to the doorskin with the shop’s Lincoln-Electric 225 Precision TIG welder. Once that is done, the reveal for the exterior door handle is pressed into the skin.  The corners of the doorskin...  The corners of the doorskin are not folded up, as it is too far to stretch the metal for such a tiny radius, so a small piece will be welded in later to make up for it. (You can also see how much space there is between the skin and the structure—almost nil).  Kent begins folding the skin...  Kent begins folding the skin over onto the structure with a hammer and dolly.  To finish the job, Kent uses...  To finish the job, Kent uses a DS1000 Door Skinner made by Astro Pneumatic Tool Company to flatten out the rest of the fold.  Vo�la! The finished, hand-fabricated...  Vo�la! The finished, hand-fabricated door. Walden’s makes the work look easy, but nothing could be farther from the truth! The work looks so good you forget this is a scratch-built body that started out as a stack of 4x8 sheetmetal. Expect to see the finished car later this year.
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