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Door Handle Delete: Because Spaceships Don’t Need Handles!

This month, we're spotlighting Phil Torrence's '69 Camaro and the custom door handle delete process.


Metal clamps hold custom sheet metal piece to the door skin on Phil Torrence's 1969 Camaro at Dutchboys Hotrods.

Welcome to our slice of hot rod heaven at Dutchboys Hotrods! Paul VanNus, co-owner of Dutchboys Hotrods, tells of a story that created inspiration for him. He used to get so excited to read the articles released every Friday by Detroit Speed Engineering. While I couldn't wait to see what the newest VHS tape was released at my local video store, Paul spent his time reading to gain the knowledge to take his talents to the next level. Like many other genius hot rod builders, this is a common trait that separates the car enthusiast from the true passionate, skilled technicians, fabricators, and builders.



Start at Easy Metal Fabrication


What is one of the biggest misconceptions about metal fabrication? "That it's easy.” -Jeff Shaw

There is a starting point for every metal fabricator. You'll see in the spy shots of our spaceship that Jeff Shaw (#mynameisJeff) is doing more than just deleting the door handles. He is completely changing the body lines, and he makes it look easy.



"Easy" is not the right term.


I am bringing you something that is usually a step in customizing your hot rod: Door Handle Delete. Your first steps may be different, as we started from a disassembled door with stripped metal. Jeff began by removing the door skin and measuring the holes he would fill, then changed his approach (#adaptandovercome).

Custom measured filler pieces for Phil Torrence's 69 Camaro bare metal passenger side door exposing the measurements and layout.
Started measuring individual holes. #metalfabrication

You'll notice two different ways to approach the task: measuring the individual holes or measuring the area of the handle and lock. In considering the endgame of managing heat saturation along with warping and metal finishing, the latter method turned out to be the best choice for Phil's Camaro.

Custom measured filler piece that covers the area for Phil Torrence's 69 Camaro bare metal passenger side door skin showing Dykem used to trace low and high spots.
Landed on measuring the area. #heatsaturation

Follow These Steps


“Trust the process.”
Custom measured filler piece that covers the area shown tacked-in to place for Phil Torrence's 69 Camaro bare metal passenger side door skin also showing the custom piece added for an improved style of body line.
Step #5 - Tack-Weld the filler piece into place. #hammerthewelds

  1. Based on your area measurements, measure and cut an oversized piece from sheet metal.

  2. Shape the metal to the door using a power hammer, planishing hammer, and an English wheel.

  3. Verify the fit: Jeff used the Pullmax to break his edge for a seamless flange edge on the door skin.

  4. Scribe the area of your oversized filler piece onto the door skin, then cut it out.

  5. Tack-weld the filler piece into place and hammer the welds.

  6. Using a continuous weld, make the filler piece one with the door skin and hammer those welds.

  7. Clean the back side of your door skin up with a wire wheel.

  8. Spray your area with Dykem, and with a hammer and dolly, fix the highs and lows.

  9. Finish with 80-grit over the area to blend with the door skin.

Custom measured filler piece that covers the area for Phil Torrence's 69 Camaro bare metal passenger side door skin is shown welded in with one continuous weld prior to hammering the welds.
Step #6- Continuous Weld

Be Inspired


Dutchboys Hotrods team is full of skill, talent, and expertise to shape, form, and create builds that meet and exceed the expectations of top- notch modern hotrods. Each step from disassembly, design, metal fabrication, machining, bodywork, paint, and assembly is an art. Stay tuned for meeting more of the Dutchboys team and tackling different tasks to make these builds 100%! #dutchboyshotrods


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