Part 10: My 76 Mazda RX-5 Cosmo Restoration - Shaved Door Sheet Metal

In part 10 of my 1976 Mazda Cosmo restoration, I continue the surprisingly long task of shaving the door handles. Last episode I left off after cutting the patch panel to fill the hole in the passenger door. This time I weld the panel in, fix the huge amount of warpage my improper welding technique caused, then do the same on the passenger side. Shaving the door handles took a lot more time than I thought it would and it feels nice to have it all finally done. Included in this episode: patching door handle holes, welding sheet metal, grinding down welds, hammering out warp caused by welding, learning how to not screw it up next time.

Category:

Autos & Vehicles

Tags:

• mazda
• rx-5
• cosmo
• ap
• restoration
• rebuild
• modding
• rotary
• wankel
• engine
• custom
• installing
• shaved
• door
• handles
• poppers
• autoloc
• solenoid
• actuators
• kit
• power
• lock
• sheet
• metal
• patch
• fitting
• cutting
• shaping
• body
• hammer
• welding
• panel
• dolley
• dolly
• warp
• straightening
• rx2
• rx3
• rx4
• rx7

[henryv8]

Great vids dude, I spent a night really enjoying this. With the patches, if you make them a couple of mm smaller you will get more room for expansion and use the weld to fill the gap. You will get alot less distortion. 

[aaroncake]

@henryv8 There was actually about 1MM between each side and the door, I just don't think the video showed it clearly. Really, I should have filled the existing handle holes instead of cutting a big chunk out of the weakest part of the door. :-)

[guilmongrowlmon]

hay aaroncake just wanted to ask you something isnt a 12a a 1.2 liter engine not a 1.1 liter engine. GO THE MIGHTY ROTARY

[aaroncake]

@guilmongrowlmon It's actually 1.1 litre.

[sjaakiepot]

there was a video i found related to yours, hes also using air to cool it down... some say aircooling or watercooling is not smart to do.. others say it is.. looks like its all personaly :P

[aaroncake]

@sjaakiepot Based on using both methods for my doors, I'd say that I'll only force cool if I want to shrink the metal. I was able to get the best results when keeping the door a constant temperature. Which probably has something to do with the fact that I cut out the wort possible section to patch, taking all the strength out of the door stamping and making it far too easy to warp. I water cooled the rockers when I filled the trim holes and didn't get any warping.

[aaroncake]

@bstnguy9 Oops, my mistake. Let me rephrase the statement so it's true then: "I haven't done that much pounding since the last time I saw your mom.". Much better and in line with reality.

[Julzilla]

"i haven't done this much pounding since the last time i saw my girlfriend" bahahahahahaha rofl good call!!!

[algurdian]

Love your work ...but maybe you should of used the old tried and true hammer-weld method.

I had great results hammer welding my my 65 mustang quarters..no warpage

[sjaakiepot]

hey man, how are you doing on part 11 ? excited to see it lol :P

[aaroncake]

@ptdude805 Haven't done any spudgun stuff in a while, but suddenly now I have the urge to dust one off and take a few shots.

[ptdude805]

man i remember seeing your site about 8 years ago when i made my spudgun. glad to see your still working on projects.