They May Be Minor BUT . . .

There are 13 doors to make in total and they go like this . . .

Cut pieces of tubing to length allowing for the gaps and edge trimmings etc..
These are cut square ended and then put into the milling machine to have a 45 degree corner mitre machined.
This means I can be cutting the next one while this is going on and is far more accurate than any other way I can think of.


















Weld the tube together to make a rectangular frame a little smaller than the opening it is going into.
Grind and dress the corners flat.


















Cut, mitre and drill welding holes on matching pieces of angle "iron".


















Fit the angle iron around the internal side of the frame with 5mm spacers in between the tube and the angle.


















Clamp everything in place


















and weld through the holes.


















Grind the weld off flush


















and prime ready for painting.


















Then the actual door seal, called "pinchweld" is pressed into the pocket created.
This will also need mitre-ing at each corner . . . a process not yet determined as this is strange stuff with a metal strip running through the part which grips the angle to provide strength so you can't just cut it with a knife!


















Then the fibreglass facing is applied to the other side


















and finally the trim angle is applied . . . again with the appropriate mitre-ing !!


















Thirteen times and only a couple of common sizes . . .
what was I thinking ?????