Long Overdue Progress! Making New Door Panels 12/8/24

[BBShark]

I will probably just do it the old fashioned way now that the weather is better. Making a huge mess outside instead of in my garage.

The giant metal eagle hanging is almost ready to take outside. It has hinged wings and sits on a pivot with a heavy counterbalance. The wind moves the bird wings slowly so it looks like its flying. I am going to paint it up like a Bald Eagle before I put it out. I'll post a picture when I get it set up

 

[BBShark]

Started on the XPS buildup of the perimeter glued to the frame:

FRAME



GLUED ON BLOCKS

 

[phantomjock]

Next step? Shaping these blocks for morphing the C-6 panels in?
These are going to be interesting.

Cheers - Jim

 

[BBShark]

This stuff is a complete mess to work with. I got most of it shaped with a saw and a Surform tool. This stuff is really sort of rubbery so a Surform tool basically rips the surface off into shreds. Then I sanded with 60 grit orbital. The glue lines will not cut or sand the adhesive and I can't really find what people are using to fair this stuff.

Here is what I have so far:

 

[BBShark]

Electric door latch finally done w/push button entry

 

[Richard454]

NICE- I use a waterproof electric roller switch- has a NO and NC outputs- Can add a relay so when the ignition is on- the switch is inoperative unless your foot is on the brake.

Also have a SS bracket made up for it. Have about a thousand of these in the field with my wiper kit- no failures!!!

 

[BBShark]

Nice product. I don't have a wiper door anymore but if I did....

 

[bobs77vet]

that push button is awesome!!!

can you use a fiber glass coat over the foam board to even it out and make sanding easier?

 

[BBShark]

Still have some tweaks to do on the cables for the latches.

The Home Depot foam I used is sort of shapeable, I see a lot of people making surfboards out of it. But my focus right now is to get the doors functional and come back to the door panels after body work and paint.