Progress 

"AestheticsInMotion" (aestheticsinmotion) 09/13/2018 at 23:32 • Filed to: None

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Time to eat humble pie. I now see why the quote was so high for “a simple door”. Nothing is square, things don’t line up in the slightest in length, width OR depth, and the original door was a terrible design in the first place. Super fl imsy. I redesigned it, but I need it to look the same from the exterior. 5 hours in, still a ways to go. 

BaconSandwich is tasty. > AestheticsInMotion 09/14/2018 at 00:28

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I still think it's awesome you are doing it yourself. It's hard to see in the photos (on a phone), but what are you using for rivets?

AestheticsInMotion > BaconSandwich is tasty. 09/14/2018 at 01:09

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Undecided. The outer frame is attached wit h hex bolts, the rivets that line the box truck are the kind that need a separate t ool on each side, not just a little r ivet gun. I figure I’ll get the door sized properly first, and then worry about the bracing and aesthetics

BaconSandwich is tasty. > AestheticsInMotion 09/14/2018 at 12:35

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If you need to do some solid riveting, Aircraft Spruce has the rivets, rivet sets (tool that goes in an air hammer), and bucking bars (solud chunk of metal you hold on the back side when hammering). I've really been wanting to learn to use solid rivets, but haven't pulled the trigger on buying any of the equipment yet.

AestheticsInMotion > BaconSandwich is tasty. 09/14/2018 at 18:33

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Thank you for that, I had no idea what the rivets and riveting tool were called. We'll see. I'd like to do it eventually, but it's a low priority 

BaconSandwich is tasty. > AestheticsInMotion 09/14/2018 at 20:38

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I hear you. I think most people would use pop rivets (technically called blind rivets - I believe “ Pop” was a brand name) and call it a day.

If you are in the US, Eastwood tools also sells some riveting material. E.g.: https://search.eastwood.com/search?p=KK&srid=S1-4DFWP&lbc=eastwood&ts=custom&pw=rivet%20set&uid=718518902&isort=score&view=grid&w=Rivet&rk=1

I still have yet to determine if any air hammer will do, or if it has to be short stroke one.