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SOONERCRUISER's Panel Van Conversion

 
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  #141 (permalink)  
Old 04 Oct 2018, 08:32 pm
rckstein's Avatar
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Default Re: SOONERCRUISER's Panel Van Conversion

Go to almost any hardware store and you will most likely find these kinds of caps to cover your exposed nuts:



I just don't want to be blamed for any catastrophe since you posted this earlier

Quote:
Originally Posted by soonercruiser View Post
OK! BLAME RCK!

I went for it today!
Just one more thing to do when I get her back!

I just really want to see them work on your PT
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'06 Touring Edition NA Automatic
160k Miles / Electric Blue Pearl
USMC '82 - '93

Last edited by rckstein; 04 Oct 2018 at 08:35 pm.
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  #142 (permalink)  
Old 04 Oct 2018, 10:24 pm
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Talking Re: SOONERCRUISER's Panel Van Conversion

Quote:
Originally Posted by rckstein View Post
Well for gosh sakes, be sure to clean them well before you show them

I always thought the end WAS supposed to be split!
rckstein and chuzz like this.
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Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!
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  #143 (permalink)  
Old 06 Oct 2018, 10:17 pm
soonercruiser's Avatar
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Default Re: SOONERCRUISER's Panel Van Conversion

Quote:
Originally Posted by rckstein View Post
Go to almost any hardware store and you will most likely find these kinds of caps to cover your exposed nuts:



I just don't want to be blamed for any catastrophe since you posted this earlier

I just really want to see them work on your PT

NUT CAPS TOO SMALL for mine !!!!


That's exactly what I had planned on doing!
I love my local Ace Hardware.
I should have bought "stock"!
__________________
Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!
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  #144 (permalink)  
Old 06 Oct 2018, 10:24 pm
rckstein's Avatar
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Default Re: SOONERCRUISER's Panel Van Conversion

Quote:
Originally Posted by soonercruiser View Post
NUT CAPS TOO SMALL for mine !!!!


That's exactly what I had planned on doing!
I love my local Ace Hardware.
I should have bought "stock"!
Then use this to cover them



But just please, just cover them
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160k Miles / Electric Blue Pearl
USMC '82 - '93
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  #145 (permalink)  
Old 06 Oct 2018, 10:50 pm
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Cool Re: SOONERCRUISER's Panel Van Conversion

Amazing progress, as I was invited up this evening to install the door poppers!

He had painted the inside of the yellow kit doors black; so I could install the door poppers!
And, he had already welded-in the driver's side qtr panel window,...and roughly mudded it in!

I told him that the other shop had taken a full day just to weld-in the qtr panel window.
His response was, "I would not hire the guy to work for me"!

He was talking about a week or so to be totally done!

It was a late start for me, as I already had a busy schedule Saturday.
So, I didn't get there until 5 PM.
But, I wanted to get the doors poppers in the door, and the power wires run to the door jam rubber conduit.

**REALLY GLAD I didn't have any bigger parts, like the grommets to install.
I could have used the hands of a 6 year old for this job.
You can mark and drill the holes....BUT....getting you fingers and the bolts around the solenoid down in that space was a PITA!

Even trying to crimp the cable on top, and screw tighten the pinch tube on the solenoid end was a real challenge.
IT took me about half the time to do the second one; as I did a lot of measuring and conjuring on the first one.
I also took a 12V battery with me to test the poppers afterwards.
***BOY! I almost jumped into the door frame the first time I popped one! 45# pull, and quick!

Here are a few pictures.

This first shot is the top end of the assembly, where the wire cable goes through a lever in the door handle mechanism toward the car's interior, which already has a hole and plastic grommet that works perfectly.
As you notice, as the instructions say, the cable is not to be pulled tight - allowing just a little slack.

The kit supplied a copper sleeve that was supposed to be crimped there.
But that tube was waaaayyy to thick, and merely fractured when finally did crimp it.
POO DESIGN!
So, our standby was crushing an electrical crimp connector.



This second picture is taken towards the bottom end of the assembly, and the solenoid.
The metal cable grommet did a great job of redirecting the pull on the cable and latch, in a downward direction.
The lower wire cable is held firm by a screw pinch tube.
That worked great, as is.
You can see a reinforcing tube that runs diagonally inside the door there, making hand space even tighter.



Lastly you see what the bolts, washers, and nuts look like protruding into the door jam.
I broken 3 Dremmel disks, just trying to cut thru one of the bolts.
So, they told me they had an air powered cutter to take care of those protruding ends.
So, once they do that, I will paint the nuts, and cover with black plastic caps held on with silicone.....as already suggested.
As such, these doors will only rarely be opened anyway.
The poppers are for the convenience of when I do want to load, or arrange the load from the side.

The guys where already working on their own classic MOPAR projects when I got there.
So, I wanted to Do It Myself.
But, yes, I'm sure a more "professional" job COULD have been done by reversing the bolt direction.

__________________
Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!

Last edited by soonercruiser; 06 Oct 2018 at 11:00 pm.
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  #146 (permalink)  
Old 08 Oct 2018, 04:25 pm
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Talking Re: SOONERCRUISER's Panel Van Conversion

MONDAY'S PROGRESS:

Over the weekend, I ordered the plastic nut caps; as I could not find them anywhere in town.

Since Jeff was finishing up buffing another car before he starts on my paint prep, I drove up around noon to do a few more things.

Here is a pic of the Driver's side Qtr panel window welded and mudded.



The I wiped LocTite on the bolt ends that they had cut off for me. Waited while doing other things; then later painted glossy black...along with a few casualty scratches.



Then, I mounted the Door Popper Controller where there is a lot of space under the trim panel above the wheel well.
I figure that I will usually be approaching the car from the driver's door side.
So, I mounted it on the passenger side, and I taped the antenna upwards where it will only be covered by plastic trim.



Then, I got Jeff's advise as to where to mount the popper spring for each door.
He has poppers on two of his Classic cars, and has already made the mistakes for me!
(You have to have 3 inches of inside depth/space for the whole spring tube to go into.)
We found that depth under where the interior trim bulges outwards, below the area of the door latch bar, where it will also push on that flat spot below the child safety latch.



Then, I went to the passenger side rear door, as the wiring comes upwards along the wheel well, and tapped into the pink wire for the cargo light!



***AHAAAA!
Now it just dawns on me that that wire has only problem!
(Even though it was suggested by someone on this forum.)
That cargo light wire will only be "hot" when I unlock the doors remotely!!!!
(as in, when the interior lights are on.)
So, I may have to do that, before I pop any rear doors.
NO BIGGIE! As I pretty much always unlock the PT by using the remote first anyway!

Jeff say he hopes to be painting by later today!
__________________
Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!

Last edited by soonercruiser; 08 Oct 2018 at 04:41 pm.
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  #147 (permalink)  
Old 08 Oct 2018, 06:54 pm
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Default Re: SOONERCRUISER's Panel Van Conversion

Quote:
Originally Posted by soonercruiser View Post
I hope you're happy now, you've traumatized me by showing your bare nuts, and what a sight they are

The nut caps I mentioned earlier may be too thick to work on the upper nuts (the redirection clamp) since the nuts are so close together, the caps will most likely hit each other and not snap on.

But you could get this kind of a vinyl cap to cover those nuts:



They have a thinner sidewall and both together should clear each other. If the length is too long, you could trim them down and the cut edge will be against the door and not show.
__________________

'06 Touring Edition NA Automatic
160k Miles / Electric Blue Pearl
USMC '82 - '93

Last edited by rckstein; 08 Oct 2018 at 07:01 pm.
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  #148 (permalink)  
Old 08 Oct 2018, 08:49 pm
soonercruiser's Avatar
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Cool Re: SOONERCRUISER's Panel Van Conversion

Quote:
Originally Posted by rckstein View Post
I hope you're happy now, you've traumatized me by showing your bare nuts, and what a sight they are

The nut caps I mentioned earlier may be too thick to work on the upper nuts (the redirection clamp) since the nuts are so close together, the caps will most likely hit each other and not snap on.

But you could get this kind of a vinyl cap to cover those nuts:



They have a thinner sidewall and both together should clear each other. If the length is too long, you could trim them down and the cut edge will be against the door and not show.
HEY!!! Those are just the PT's NUTS!
Pictures of mine to come!

The set of caps I ordered are hexagonal inside, and in varying sizes.
I will probably grind them down and ensure they do not hit the door jams.

__________________
Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!
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  #149 (permalink)  
Old 08 Oct 2018, 08:53 pm
soonercruiser's Avatar
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Talking Re: SOONERCRUISER's Panel Van Conversion

Here ya go!


rckstein likes this.
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Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!
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  #150 (permalink)  
Old 11 Oct 2018, 07:05 pm
soonercruiser's Avatar
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Default Re: SOONERCRUISER's Panel Van Conversion

Cruiser should be the paint booth tomorrow for Primer and inspection!
__________________
Frank, aka SOONERCRUISER,

2011 GWE Dodge Challenger SRT8 as Show Car
2003 PT Cruiser GT as the new Day Driver - being converted to a Panel PT

Have now owned 6 PT Cruisers = Me PT Crazy!
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