223 Nearside foam build up through wheelarch. A good idea of what is required to achieve the desired effect.
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| 224-Nearside foam buildup. I used P40 to give this area a basic protective coating and will glass this area later. Note the P40 buildup around the ball joint mounting to shape this to clear the hinge again as per original design. I also extended the 'A' pillar adjustments I made for the inclusion of the secondary rubber weather strip at the same time. This can be seen here.
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| 225- Inside door mounting- to minimise sway in ther doors I decided to add some structure to the hinge area- The problem is that the only attachment for the hinge is a small plate, so I created a 'sandwich' of another plate that extended down the whole curve inside the door and glassed this in- here you can see this before the glass goes on. Also shown is the mounting for the aluminium side bars detailed later.
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| 226- Door bar structural fitment- In addition to the metal all the way down the door I cut out the back to access the hinge area inside the door and added a separate metal 1/4in bar to the vertical part of the door and welded this to the plate for additional strength.
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| 227- Inside door bar fitment lock side- Here you can see the other side of the door where I also added a double welded plate (seen before glassing into the door)to attach the side impact bars I made up. This now gives me longitudial strength all the way across the door and reduces the sway when bringing the door down to the lock. The aluminium bars can be see in the next picture and attach to the bolts shown here as well as at the other side near the hinge.
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228- Door bars in Nearside door- after extensive reworking of the hinges I glassed in metal plates to both door sides of the door( hinge and lock sides)- these extend right up to the top and via bolts are directly connected to the hinges- then I made up door bars from aluminium bars. Bolted in place these stop door sway and give me some side impact protection :-) I've now eliminated 95% of door side to side movement- I've finally decided this is the best its going to get... short of original doors.
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| 229- Drivers door lip being reworked for better seal. Here we go again!! I reworked the door lip on the drivers door to stop water ingress. Nearly there now. I've totally replaced the entire seal all the way round on BOTH doors to get an even seal. This is the last section.....
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| 230- Door back on and adding filler to build up to meet the wing. More detail in the Body gallery...
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| 231- Just about the hardest part of any build. Just take a look at all that hardware in situ!
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