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: