G28 - Simple Mans, Simple REDO of an G28 LP640

[Simple Man]

Progress on the latch area of the Door.  The fiberglass where the latch mounts was warped as well. 

It takes time to let the multiple layers of Fiberglass cure.  I can see why the PO just loaded it up on Rage filler     

For the corner it took 9 layers and the latch area 6. At least The REDO doors will have a thin layer of dyna glass and rage.

The  inner and outer doors line up pretty good in the latch area now

[Simple Man]

Master of glass....

Im not sure about that 

[Simple Man]

While waiting for the fiber glass to cure, the new custom front sway bar was installed.  It solved two problems, the coil over was rubbing on the OEM sway bar, and it wasn't not long enough.

Now the angle is better with the Rodney Dickman Zero Lash End Links. And it doesn't touch the coil overs

Looking through old pictures, the REDO's front end has come a long way!!

[Footcutter]

Master of glass....

[Simple Man]

The inner door is hitting on the lower rear corner. Which is not allowing it to go back the 1/2" needed.  I added material on the inside and took material off the outside.  It is getting close.   Added another 3 layers, and will grind it down tomorrow.

Might have been quicker to pull a mold off the door that came with the REDO  and fiberglass it to the new inner door.... but too late for that now

[Simple Man]

Nice work. 

 it only just beginning    "all I want for Christmas is my two front teeth I mean doors " with power windows   

[Footcutter]

 Nice work. 

[Simple Man]

Started working on the doors yesterday.  Had my new used latch for the drivers side and some thing was off .  After looking at numerous pictures of latch installs on this website the PO had installed the passenger side latch on the drivers side. 

So the Striker plate is in the wrong position and will require a REDO. 

I test fitted the inner door.  With the inner door clamped in place I test fitted the outer skin.
Need to move inner door to the rear 1/2 inch, this will require fixing a few things.
lower right corner and upper vertical piece. The front isn't sealing so the gap needs to be closed.

[Simple Man]

My buddy with the machine shop did the REDO on the Arruat bushings. 

the 1st two pictures are the Arruat fit   The 2nd two are the REDOs

A tighter fit is always good !!

Hoping I can put Arruat behind me now!!

[Footcutter]

We should all be so lucky.  I admire your patients on getting things right!

[Simple Man]

I am happy, and sad for you...

thanks man.  He was 91 and had a great life, did a lot of traveling and was retired for 32 years!!!

[Footcutter]

I am happy, and sad for you...

[Simple Man]

The flanges are almost done on the driver door. The roof now has a flange and the lower flange is now straight.

I also added the flange just under the windshield,  not sure what type of weather strip goes there   

The flange that is horizontal and toward the front of the car will require some REDO as it is pretty flimsy as it was ground down and cracked in places.

[Simple Man]

Back on the REDO after 24 days off.  Went to Italy and toured the Lambo and Maserati factories ,  Then caught the stomach flu when we  got home  .  Then my gals father passed last week. Things are slowly returning to normal......

[Simple Man]

Absolutely impressive the amount of work you are getting done in such a short amount of time! Keep it up and you'll be done in no time!!! 

Thanks LP670!   It was 2 years a go that I flew out to take a look at the REDO.  The PO pretty cool guy and very helpful.

In the 2 years I think I have accomplished at lot on the car but have a long way to go!

I'm having a blast working on the REDO!

Thank to all that have offered help, suggestions and encouragement - but specifically Merci-Me, Autopro, USMC Butler, Fiero King, Lambo Sam and yes the prior owner   

Got zero done this weekend heading out today for a vacation with my gal. Be back on it after Thanksgiving!!