Every Road Leads Home said:
Love seeing the updates. Looks like you barely had a half inch to spare when mounting that door between running out of space at either the top or bottom of the rig. I say great job getting that in there so nicely. I'm in a half finished house at the moment and cuss and curse at the lack of space or facilities at times and can only imagine that the inconvenience factor magnifies 10x when doing it in a vehicle. Hats off to you for taking on such a project with no dedicated shop or land to do it on. It's inspiring to watch it all unfold.
Door:
You are exactly right about the door fit. When it was time to buy the door, due to various circumstances, I had minutes to decide if it was going to work or not / buy it or not. After some rushed measuring of the truck and the door, I decided to buy it. However, I was never sure it was going to fit until a week or so later when I cut the hole in the side of the truck. And it took me some part of three days of measuring and thinking before I finally put a saw on the wall.
In the end, there is exactly one half inch between the top of the door frame and the bottom of the upper aluminum rail of the box. I'm amazed that you could spot that so exactly from my bad photo. What an eagle eye! On the bottom, the door frame rests right on the lower aluminum railing of the box.
One of the trickiest mental challenges was realizing that the door needed to be mounted in such a way that it would be lower than the interior floor of the box. Even though I knew it was an outward opening door, some reptilian part of my brain kept throwing up roadblocks with the thought that the bottom of the door and the floor inside the box needed to be at the same height. Not true, of course, because that only applies to an inward swinging door. But it went beyond realizing that.
I had to come to realize that, with the door needing to be installed below floor level, I had to cut out part of the brand new floor that I had just installed to allow the door to go into the frame. Talk about counterintuitive and red flags! Once I figured all that out, it was just grunt work from there. In the end, the door fit in that space hand in glove. I could not have been happier about that.
Inspiring:
Glad to know that the updates are worthwhile on the other end as well. I would say that this project inspires me about 10% of the time. About 80% of the time it's just relentless focus on the mission. The other 10% of the time the stress brings me close to puking my guts out. So, all in all, interesting project soup to swim in.
As always, I appreciate all comments, especially the encouragement from experienced people I know really mean it.
Tom