Re: [DML] Re: Doors / jigs
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Re: [DML] Re: Doors / jigs

 It looks like the short term cure created long term difficulties. There are several components, such as the lock rods, the hinges, the striker bolts, that are designed to be adjustable in their positioning -parts that aren't, and don't need to be adjustable on "normal" cars. Handy for adjusting in the manufacturing facility, to compensate for less than precise parts interchangeability. On the other hand, a major pain if they get out of alignment in the field. I once asked someone at DMCH (maybe Warren?) why they don't just develop an upgraded door lock rod set of standardized lengths, to eliminate misadjustment issues and was told it was impossible. Not consistent from car to car. It wouldn't have hurt for the rods... at least the longest one... to have been sturdier, too. It's a tad floppy, even with the little plastic guide loop in place. The rods inside the doors of a Plymouth Neon, for instance,  are not only sturdier, but way shorter, leading to no flex whatsoever. Wouldn't it be great if someone could develop a set of jigs. But from the sound of it, even the factory didn't have or couldn't develop jigs. 




-----Original Message-----
From: content22207 <brobertson@xxxxxxxxxxxx>
To: dmcnews <dmcnews@xxxxxxxxxxxxxxx>
Sent: Sat, Mar 17, 2012 2:04 pm
Subject: [DML] Re: Doors

Doors proved so problematic that the entire assembly sequence was changed to 
accommodate them. Two doors were matched to a specific underbody then 
laboriously test fitted until they worked well enough. Only then was the 
underbody, with the doors already attached, transferred to a chassis on a Tellus 

Here's a shot of underbodies and doors, in matched pairs, lined up along the 
outside wall of the assembly building:

This shot shows cars with doors already in place before other body panels, 
interiors, and in some cases even wheels attached:

Gullwing doors are a nice styling feature, but in assembly line manufacture they 
proved to be a nightmare.

Bill Robertson

--- In dmcnews@xxxxxxxxxxxxxxx, "jtrealtywebspannet" <jtrealty@...> wrote:
> My guess how the factory did it, they probably did a few by trial and error 
and once they got it good they made up a gauge or template so they could 
position and tighten the hinges. They may have had to "fine tune" it on each car 
but at least they were close. 


[Non-text portions of this message have been removed]


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