Restoring a classic car often involves removing the body from the chassis, a process that can compromise structural rigidity. This loss of rigidity can lead to misaligned doors, making reassembly a frustrating experience. A Car Door Gap Tool helps maintain the correct spacing, ensuring proper alignment throughout the restoration. This article details a cost-effective DIY solution for creating your own car door gap tool, inspired by a restoration project on a classic Triumph.
Maintaining Door Alignment During Restoration
Removing a car body, especially when replacing floor pans, can cause the body to flex and bend. This makes aligning the doors after the bodywork is complete a significant challenge. While professional car door gap tools are available, they can be expensive. This DIY approach offers a budget-friendly alternative without compromising functionality. This method uses adjustable metal plates and threaded rods to brace the door openings and prevent unwanted movement during the restoration process.
Constructing the DIY Car Door Gap Tool
This DIY car door gap tool is designed for a Triumph TR6 (round tail) but can be adapted for other models. It consists of two main components: door gap adjusters and a bracing tool. Both utilize similar metal plates and threaded rods.
Door Gap Adjusters
These adjusters consist of two metal plates that clamp onto the door opening where the weatherstripping sits. A threaded rod connects the plates, allowing for precise adjustment of the gap.
Bracing Tool
The bracing tool utilizes the same type of plates as the door gap adjusters. One set clamps onto a seam under the dashboard. A threaded rod connects these plates to a piece of angle iron bolted to the rear hardtop mounting points. This creates a rigid structure that prevents the body from flexing.
Materials Needed:
- Steel Plates: 10 plates, 100mm x 100mm x 6mm, with pre-drilled holes (see diagram below – diagram not included in this text version)
- Angle Iron: 600mm length, 40mm x 40mm x 5mm, with pre-drilled holes and slots (see diagram below – diagram not included in this text version)
- Steel Tubing: 6 pieces, 50mm length, 24mm Inner Diameter (ID), thick-walled
- Bolts: 20 M10 x 35mm bolts, 2 M8 x 40mm bolts
- Washers: 50 M10 flat washers, 6 M8 flat washers, 12 M20 flat washers
- Nuts: 20 M10 hex nuts, 2 M6 hex nuts, 12 M20 hex nuts
- Threaded Rod: 1 meter of M20 threaded rod, 1.5 meters of M20 threaded rod
(Note: Original design used M10 threaded rod and 12mm ID tubing, but M20 and 24mm ID are recommended for increased strength and ease of assembly.) Using thicker walled tubing and a slightly oversized ID for the tubing will make it easier to fit the washers and nuts onto the threaded rod.
Cost Comparison
This DIY car door gap tool can be constructed for significantly less than the cost of a commercially available option. The estimated cost for the materials is less than $40, a fraction of the price of pre-made tools.
Conclusion
This DIY car door gap tool offers a practical and affordable solution for maintaining body rigidity during classic car restorations. By using readily available materials and simple construction techniques, enthusiasts can ensure accurate door alignment and avoid potential headaches during reassembly. This method provides a strong and adjustable bracing system, crucial for a successful restoration project. While M10 threaded rod was used in the original construction, upgrading to M20 rod provides a more robust solution for preventing body flex.
