In the last two issues, we have been covering how the crew at C. Hopkins Rod & Custom in Commerce, Georgia, has been resurrecting an original SS396 '67 Chevelle, dubbed the AMD Chevelle. The idea of this project is to show you how to take a worn out musclecar and transform it into an assembly-line-fresh piece, using high-quality new sheetmetal from Auto Metal Direct (AMD). The work on this car is pretty extensive, so think of this as a worst case scenario build. The first story showed how to properly strip the car down to a bare skeleton in preparation for all the new AMD sheetmetal. The second story showed new floor, quarters, roof, and other panels being welded in place. This installment will show the proper procedure to re-skin a door with AMD's GM-licensed door skin. Handling the restoration will be Craig Hopkins and his team: son Aaron Hopkins, Caesar Brecino, and Chris Dyer. Craig's shop is Auto Metal Direct's main installation and R&D center, so we have one of the premier crews doing the work. 1 We left off last month with the car having its new skin installed, including a new floor system, roof, and quarters. We now follow along as Craig installs this new door skin from Auto Metal Direct. The door skin is OE thickness and comes EDP coated. EDP—or Electrophoretically Deposited Paint—coating is applied electrically, much like a plating process. It leaves an excellent rust-resistant coating that reaches every area of the panel.1 We left off last month with the car having its new skin installed, including a new floo 2 Before the new skin can be installed, the original door assembly needs to be hung on the car and made sure it will line up. You also want to look for issues with the inner door structure, like cracks around the hinge attachment points. If there are a few small cracks, those can be welded up. But, if it’s pretty bad or shows signs of damage from a crash, you might want to look at purchasing an entire door not just the skin. This door passes all the checks, so Craig can continue with the job.2 Before the new skin can be installed, the original door assembly needs to be hung on th 3 This part needs to be removed from the door first. It’s the inner upper support bar and is welded to the door where the felt attaches. It’s there to stiffen the door skin and also tie into the vent window assembly. The spot welds are drilled through to remove this piece from the original skin.3 This part needs to be removed from the door first. It’s the inner upper support bar and 4 The door skins are just folded over the inner structure then welded in a few places. Instead of taking a bunch of time unbending the fold, Craig just grinds through the edge then uses an air hammer with a chisel bit to strip off the welded part, shown here.4 The door skins are just folded over the inner structure then welded in a few places. In 5 If done correctly and with care, you are left with an unmolested inner structure.5 If done correctly and with care, you are left with an unmolested inner structure. 6 Craig blasts this piece and then coats it in DuPont DTM 25105 Direct to Metal Epoxy sealer tinted to match the factory red oxide.6 Craig blasts this piece and then coats it in DuPont DTM 25105 Direct to Metal Epoxy sea 7 Craig drills a few small holes along the seal area of the skin so he can plug-weld on the brace removed earlier.7 Craig drills a few small holes along the seal area of the skin so he can plug-weld on t 8 He also cleans up the surface where the brace attaches to make sure it mates up flat and to also remove the EDP for a better weld.8 He also cleans up the surface where the brace attaches to make sure it mates up flat an 9 The brace is lined up where it was before and then plug-welded through the holes drilled earlier.9 The brace is lined up where it was before and then plug-welded through the holes drille 10 Small sections along the edge are cleaned of the EDP coating for welding later on.10 Small sections along the edge are cleaned of the EDP coating for welding later on. 11 Now the inner structure is dropped on the skin, lined up, and clamped in place.11 Now the inner structure is dropped on the skin, lined up, and clamped in place. 12 With a low-crown body hammer and heel dolly, Craig slowly works the edge of the skin to fold it over. Craig folds over the areas by the corners first then comes back and folds the area in between. The top corner at the front is the most critical area, or indexing point, so the first bends are made there.12 With a low-crown body hammer and heel dolly, Craig slowly works the edge of the skin t 13 Here’s the edge completely folded over. 14 Now Craig comes back with a drill fitted with a 3/16 bit and drills a bunch of holes through the folded portion of the skin but not all the way through the inner structure. These holes will be plug-welded, locking the skin to the inner structure …14 Now Craig comes back with a drill fitted with a 3/16 bit and drills a bunch of holes t 15 … but not before the door is re-hung on the car to make sure it all lines up.15 … but not before the door is re-hung on the car to make sure it all lines up. 16 Craig makes sure all the gaps and bodylines are perfect. If they are off, he still has the ability to nudge the skin a little bit. Since Craig did all the pre-checks with the door in its original form and carefully installed the new skin, everything lined up on the first shot.16 Craig makes sure all the gaps and bodylines are perfect. If they are off, he still has 17 Now he breaks out his Lincoln SP175 MIG welder and plug-welds the drilled holes, locking the skin to the inner structure to create a new door assembly.17 Now he breaks out his Lincoln SP175 MIG welder and plug-welds the drilled holes, locki 18 That completes this chapter in the AMD Chevelle build. Come by next month to see the front sheetmetal being installed and lined up, and the grille and other bright work being dry-fitted before paint.18 That completes this chapter in the AMD Chevelle build. Come by next month to see the f SOURCES Auto Metal Direct 940 Sherwin Parkway Suite 180 Buford GA 30518 866-684-5942 www.autometaldirect.com C. Hopkins Rod & Custom 7314 Hwy 115 E. Cleveland GA 30528 706-348-6653 www.theinstallationcenter.com By Calin Head Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!
