Ok, my truck is a '51 GMC 5 window. Pretty good shape with the exception of what looks like a right front hit sometime in its past. Found a repair plate on the inside of the right side frame and the passenger side door was jammed so tight I had to use a very large pry bar to initially open the door.
After that I sand blasted and primed the cab, rebuilt the hinges and repaired the floor, cab corners, footwell, lower cowl inner and outer; the usual.
Spent many, many hours trying to gap the passenger side door. The drivers side door was a snap! The guy that I had purchased the truck from has several regular and big trucks and said he had a good passenger side door. Kool I thought but after bringing it home I realized it was the later, push button door!!!!!
Hung the door with the hinges that came with it and behold, it was not twisted or warped and gapped very well. Now to the hard part. Do I call him back or modify the door? After searching the site and several people saying it could not be done I decided to do stupid
The problem with the later model doors is that the opening for the handle is too big. So first thing was to cut out a piece of 16 ga and weld up the latch opening.
Since I had both doors next to each other I tried to mark off the location of the '51 handle opening. Three holes:
first hole is about 1/2" in diameter for the early handle, second hole is about 1" in diameter for the handle/square rod, and the third hole is about 1/4" for the blind nut to hold the front hole in the handle.
The later door needs a little work with a die grinder/carbide burr to clean up the backside of the handle reinforcing plate.
The first hole is a little tricky because it goes through the existing trailing edge of the door where the first stamped step is. 1/4". I got too close to the edge and had to tack in a piece of 16 ga to repair.
The big hole I cut with a regular hole saw and used the die grinder to clean it up.
The last hole is kinda tricky because you have to locate the handle and backing plate to get them level.
Shifting to the latch itself you need to create a small channel in the bottom of the existing door for the early model latch and remove the edge of the existing hole to where the older style latch will rest flat against the door inner. It makes sense once you position the latch.
Ok, now to the screws that hold the door latch in place.
Three screw holes but in the wrong places, duh.
Welded all three up and ground smooth. Then using the'51 door I marked off the new holes. Started with 1/8" bit to make sure I was close. Well, I was pretty close but it required a little burr work and a step bit but I finally got the latch positioned. I used 1/4 x 20 x 1 counter sunk stainless with phillips head screws. Do not have a dimple tool so just kept running them in/out and tightening to create a counter sunk area. The sheet metal is not too thick but it takes patience.
There is a triangular opening for the door latch to attach to the handle rod. The later model door opening is too small so I made a template from the early door and enlarged. Kinda big but even a standard door panel will cover.
There is also a small 1/4" slot above the opening to pull the latch into the door. Took a couple of tries to get it right but it helps to stabilize the latch.
Took about 2 hrs to do. A little welding, a little grinding, many mistakes but I now have a nice fitting door with correct handle and vent window!
Almost forgot about the third hole for the handle. The early door uses a blind nut to secure the front edge of the handle. 1/4 x 20. Used a shouldered nut with flat washer and a little bit of 3M panel bond. I couldn't get my MIG into that space. Used the carbide burr to clean up the inside and then buttered up the washer/nut and used a plain old bolt to hold it till it set up. 3M panel body adhesive has almost the same tensile strength as a weld and is waterproof! Takes about 45 minutes to setup. I left mine overnight and carefully removed the bolt. A little on the threads but nothing serious.
I have pictures that I will post on 67-72chevy.com under my user name.
