Stainless Access Door for LBC proofer part 1

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Access door for LBC, 2 door, roll-in, proofer. [This is a programmable, variable heat and humidity, holding area for cooked pans of food to maintain them at the proper temperature until serving.]http://www.weldingweb.com/attachment...9&d=1195881534Customer is a local jail that serves up to 400 meals.....so meal prep is a rather large, industrial-sized chore. I've been in the kitchen when this is going on. (The food served, isn’t fancy--but I like it! There’s worse places to be than in a California jail.)This unit is designed to be assembled and erected in place--while jail maintenance supervisor realizes, he cannot access items behind this stainless, canopy cover--for installation or maintenance--without removing the entire canopy, which is not an option for him. An access cover is required to be installed in this canopy---due to lack of foresight by the manufacturer. Designed in the U.S.---made in China, maybe with some Chinese design ‘help’, as well. Layout scribe lines for cutting door opening-below. This canopy is .038 thick--20 gauge 304 Stainless (SS). This assembly is woefully too flexible, springy and really isn’t suited for an access door cutout. IOW-it’s going to be problematic.http://www.weldingweb.com/attachment...1&d=1195881694The opening was cut with 1/16” x 3” dia. die grinder wheel, after drilling  (4) 1/8” dia. corner radius holes.After the door panel was cutout, it was then narrowed .500 to allow for the hinge barrel clearance.A .090 leaf thickness, .250 dia. SS piano hinge is used, with .093 dia. pilot holes drilled in both leaves. Below, the pilot holes are transferred into the canopy skin. *****TIP--After scribing the cutout outline of the door opening, it would have been much easier to drill the pilot holes--PRIOR TO CUTTING OUT THE DOOR PANEL---in the door panel cutout area, instead of just the canopy side.http://www.weldingweb.com/attachment...1&d=1195881804Below:The hinge leaves are drilled .250 dia.; while the canopy and cutout door are drilled at .3125 dia, to allow for alignment clearance.Hougen slug cutters are used, seen below. These cutters use a .125 dia. pilot mandrel. Using .093 pilot holes allows for accurate hole transferring from the hinge leaves and serves as a positive, accurate centering hole for the .125 dia. slug cutter’s mandrel. Both ends of the hinge pin arelightly fusion welded, to prevent pin movement and for SECURITY.http://www.weldingweb.com/attachment...1&d=1195882002Below, the door is clamped to the bolted hinge and pilot drilled.http://www.weldingweb.com/attachment...1&d=1195882089 Attached ImagesLast edited by dave powelson; 11-24-2007 at 12:48 AM.Blackbird