G28 - Simple Mans, Simple REDO of an G28 LP640

[Simple Man]

I think the REDO on the drivers door is headed in the right direction.

Here is a picture of the Old door install before the driver side A pillars width was increased. Alignment not so good.

Here is the REDO alignment  better

[Simple Man]

Tested to see if the door hit the fender in the raised position.  Attached frame to hinge with two spot welds.  Then taped the outer skin to the inner

Test was a success, the outer door skin cleared the fender with a small gap between the two panels

[Simple Man]

Made the frame for the Door. 

The old door was attached to the frame in one location, which to me seemed iffy. 

I will be making a frame so the hinge will be attached to the REDO frame on three sides.

[Simple Man]

Your fiberglass skills are awesome,  you are doing a very good job on those pieces.  Lining them up properly now will make it so much easier for you when it comes time for the bodywork phase.

Thanks !!!

[autopro]

Your fiberglass skills are awesome,  you are doing a very good job on those pieces.  Lining them up properly now will make it so much easier for you when it comes time for the bodywork phase.

[Footcutter]

 

[Simple Man]

To fill the gap between the inner door and the front seal the door length had to be increased.

Once a good seal was obtained,  the curved piece was fiber-glassed in

[Simple Man]

Now that the inner door is pushed back to the correct position the issue now moved to the wheel well area.  I have a huge gap.

When compared to the Old doors the shape is completely different.

 The old door has a hump in the curved part the new door does not.  The old door is longer. The new door is warped pretty badly.

Decided to make my own curved section for the inner door.

[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.