G28 - Simple Mans, Simple REDO of an G28 LP640

[Simple Man]

Took a ton of time to fabricate the handle support.

 I had fond memories of this massive erector set my dad bought me when I was in second grade 

Ordered up a remote door lock and unlock system.

 While Im waiting around, made additional adjustments and fiber-glassed the outer door skin  (again). 

Next is the reinstall of the window glass and mounting of the OEM outer wind sweep.

[Simple Man]

The OEM Latch is mounted lower than the G28 latch location.

The engine bonnet release handle had to be moved lower as well.

[Simple Man]

Decided to go with the W115 latch, Instead of the W126.   Got the OEM measurements from Auto pro as well as a replica upper gasket.  Thank you AutoPro!!

The OEM lower gasket really wont work without major mods to the G28 inner door.  Made my own cover. 

[Simple Man]

Good job on that door handle, getting those installed and lined up is not as easy as it seems.

Thanks!! Only one spot needs about 1/16 of an inch of dyna glass.   Took my time, made the opening a bit smaller and carefully sanded....

Pretty much following your blue print for the way you did your latch and handle set up.  Appreciate the pictures in your build thread.



 

[autopro]

Good job on that door handle, getting those installed and lined up is not as easy as it seems.

[Simple Man]

A test fit of the door..... skin fits a lot better.  Getting there

Still have some adjustments to do, really ? 

The horizontal body line that runs between the door and rear qtr panel, align nicely.

[Simple Man]

The outer skin when on the car is not in alignment with the body

The PO took a lot of fiberglass off the body to make it align with the old G28 door.

Also the NEW door skin needs to be lengthened by about 1/4 inch.

Grind, fiberglass, cure.  Turn over, repeat.

[Simple Man]

Here is the handle set up

took a little work to clean it up.

[Simple Man]

The REDO's new outer door skins appear to be OEM sized where the door handle goes as opposed to the G28 size 

Thanks Auto-Pro for the measurement on the location of the handle, mine will be close

[autopro]

That panel did come out great man, that's a great idea using the original car for the mold.  Now that area of your car will look like the OEM car. 

[Simple Man]

That sail panel came out great! How did you make the plug for the mold? (Or how did you make the mold itself?)

Thanks.  Yes, I like the smooth gel coat finish. 

Murci - Me gave me the idea about the panel as it will look more OEM

For the plug  I used the car it self,   sanded, pva, gel coat, 8 layers CSM, then sanded the mold 600-1500 grit,  filled in a few imperfections, sanded.

[Simple Man]

Can you come to Colorado and make me a dash?    JK

Nice work!

Thanks!  but I'm so swamped at work hard to find time to work on my door

[Neils88]

That sail panel came out great! How did you make the plug for the mold? (Or how did you make the mold itself?)

[Footcutter]

Can you come to Colorado and make me a dash?    JK

Nice work!

[Simple Man]

While waiting on my window tracks.  I made a sail panel mold and then made the part.

Pretty happy how it came out.