G28 - Simple Mans, Simple REDO of an G28 LP640

[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. 

[RT]

Simple Man...
The best you can do with how much glass ends up above your window opening when the glass is all the way down will depend on how far down the glass (and what holds the glass) can go until it contacts the bottom inside of your door.  If there is anything you see that can be trimmed or adjusted to get a better result, give it a try but don't expect too much.
I see the measurement you took and just remember you will also have an inner door panel with upholstery that will be up  little higher than the inside door panel, so that measurement will become less when you are finished your build.  All side windows on these cars will be exposed some when down so don't be too concerned.  You appear to be in the ballpark.
You are doing a great job.

RT

[Simple Man]

Bonded the metal door frame to the inner door.  Got a new set of tracks as the one from the pick n pull was rusted.

Got everything reinstalled and the new maxima track is waaay better.  Now to work on getting the outer skin to fit correctly.

About 3.25 inches of glass stick up above the door sill

[Simple Man]

When Murci-Me let me pull a center console from the mold he had, I made a mold to make the  console switch plate.  It took me a while to locate the part     yes that is PVA on the part..


Added the Audi switch and replica switch frame.  The wiring, relays, switch and motor all work great!       

 

[Simple Man]

Took the door apart and prepped and painted the frame.  While the paint was drying  sorted out  the Fiero power window wiring and added a couple of relays, worked out nice to be able to use the exisitng wiring 

I have spent a lot of time on that work stool lately 

[Simple Man]

Good job on lining up that door, not an easy feat.  Even the door glass on the original Murcielago doesn't roll all the way down, so if yours sticks up it means it's perfect!

Thanks Autopro!  biggest problem Im facing right now is finding the time, work looks to be pretty intense through the end of June. With Saturday afternoons being the only free time I have for the REDO. 

Liking the way your build is coming out !!