The areas that have no more blue is where it's hitting so let's see what
I can do.
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I'm using a 45 degree cutter to create some much needed
clearance here. I made my chamfer size about half the thickness of my
material and checked my progress. That still wasn't enough so I removed
a small amount more and things were much better now.
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I went back to the welder but I didn't run a bead like I
normally would, instead I 'stitch welded' it. Stitch welding is just
what it sounds like, you make a series of tack welds until it's fully
welded. It's not pretty but it works. The reason: I didn't want anymore
heat than absolutely necessary. A little weld here, then let it cool,
and repeat.
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Now it's time to fit the door better so I took out the
sandpaper. This was a long process because it's not easy to remove
material this way, but that's what I needed to do. Every time I did
some sanding, then clean off all the grit, it would fit better. After
about an hour of this, I was happy with the fit.
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I hit the weld with my Dremel and a sanding drum to clean things up. It looks much better
now but I have plans for this later.
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I have more good news and bad news. The good news is that
the door moves really good. However, the bad news is I have a new
problem, the door won't close anymore (as I shake my head from side to
side again)!!!
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As you can see the box I made now hits the inside of the
door frame. At first I had no idea why but then it hit me, I moved the
hinges with the shims. Well that was just enough to mess me up. And just
like that I have another thing to fix.
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The fix will be to remove material from the door frame,
not very much, but some. Here I'm making sure things are straight and
then it's time to take a cut.
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I used a 1/8" diameter end mill for this because it matched the radius
in the corner. I took about .025" and now the door fits good again.
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