G28 - Simple Mans, Simple REDO of an G28 LP640

[usmc_butler]

Wow well done! That could help many G28 builders if you decide to make more from the molds! Door cards were never available except from Mike Chase which I’m not sure if he makes them any longer. 

[Simple Man 2.0]

The REDO door cards   

Passenger side turn out pretty nice - learned from my mistakes on the drivers side 

Driver side - going to have to make another mold of the main piece for the card as it is pretty chunky as it was the first one I did

[Simple Man 2.0]

The REDO is using OEM grab handles.

Made brackets and welded to the door at the OEM grab handle attachment point, with weld nuts on the back side.

Easier to attached brackets and mount door cards prior to putting outer door skin on 

[Simple Man 2.0]

many adjustments to the parts pulled from the molds.  Cut and adjust, grind fiberglass repeat!!

lost track of how many times and what was done to make them decent.

be so much easier if G28 was the same size as OEM

[Simple Man 2.0]

Starting with foam to make a plug.

Lots of adjusting and then bondo sanding etc.

once the plugs were done made some molds
And had to sand the molds

[Simple Man 2.0]

Had a set of G28 door cards which are far from the look the REDO needs.  Also a set of mangled OEM replicas that were cut in the center to make them fit the opening of the G28

[Superman]

Glad we kinda got it fixed! Looking forward to some progress again!

[Simple Man 2.0]

Not sure what happened but I'm back as Simple Man 2.0  !!

Been working on custom door cards will post soon

Thanks Dustin!

[usmc_butler]

He messaged me and is locked out of his account somehow, I’ll tell him you want him to email you.

[italianknightrider]

email me at : italianknightrider@yahoo.com

[Simple Man]

rare day of sunshine   

final adjustments on passenger door - warped on the area that meets up with the outer door sweep CSM Duraglass etc - just need a bit of warm weather and i will bond the outer skin 

extend bat wing -  Something that needed to be done, used foam then CSM, dura glass

guide coat and a bit of body blocking- like the body work part of the build the best

[Simple Man]

soldered and wrapped the door wiring

install interior door release cable and handle

mounted outer window sweep

adjusted outer door skin for bonding.  Forgot just how much adjusting they needed     and still more to do

[Simple Man]

Basically giving up on doing any more body work for the next few months with the weather.

So on to inside projects

What to get my passenger door finished
so I can bond the  outer door skin

-Installed remote door lock actuator
-OEM door lock switch wired up
-Audi power window switch with relays
-Courtesy light on/off switch integrated to Door latch like OEM
-Routed wires  final connection

Amazingly only blew one fuse 

[Simple Man]

details of the fiberglass trunk build

the box was fiber glassed to the shelf

[Simple Man]

did some fiberglass work for the trunk area.

Thanks to Murcie me for the pictures of his set up, very helpful

Need a light and some grills

have a bit of work to do on a couple of pieces but over all pretty happy they way it turned out

First picture Is the REDO when I went to look at it to buy