batbuilder's LP640 called "No Mercie"

[batbuilder]

Here tape backing up the upper inner door. You can also see a massive amount of the inner door around the latch cut off. That will have to be reconstructed.

[batbuilder]

The fiberglass is measured up and ready to be glassed up, I welded that plate steel near the bottom of the door for the electric window motor. But as it is the motor didn't line up with the plate so I had to cut it off anyways.

[batbuilder]

Here is the area around the gas shock and hinge area that needed to be tightened up

[batbuilder]

The front was a little overcut but we were trying to get the inner door panel to lay down correctly

[batbuilder]

Here is the window frame that needed to be sliced to lay down flat on the seal

[batbuilder]

The latch are was completely cut away but using foamboard and tape I will be able to recreate the latch mount. It was important to leave the cut ends open so the fiberglass will bond to this area

[batbuilder]

The batwing is off so we needed to start at the body and work back towards the hinge

[batbuilder]

Here's another angle

[batbuilder]

The lip of the cut louver is still there at the ends. My understanding is the engine glass lines up with exactly where the louvers were.

[batbuilder]

The louvers have been cut off of the rear deck lid. The two side runners have to be tilted inward to match the  roof. The rear part was cut and grinded to be extended and lowered to match the rear bodylines.

[batbuilder]

Here I did use longer strips to eliminate as many splices. I also overlapped and doubled up the matting

[batbuilder]

This part is really fun. I enjoy trying to create a new piece.

[batbuilder]

Here we are laying out the part that will eventually be a door tab. the fiberglass will follow the contours of the inner door panel.

[batbuilder]

Cutting the fiberglass mat that will be used to create that door tab. Important to measure and cut before you start to glass.

[batbuilder]

Here is the interior arm rest. as we were flattening them out I realized we needed to create an indentation to act as a handhold.