I bought an electric door release setup about a year ago and have finally gotten around to attempting to shave my door handles. I bought a couple of door panels from a forum member (thanks Mark) to expedite the project. I also wanted panels that didn't have the aero moulding to flow better with the rockers that I had Archie install. Here is my progress so far...
The victims...
Marked out the cut.
I used a sears roto zip type tool - worked great!
The handle cut out.
Marked a template out of cardboard for the plug.
Taking measurements for the next cut.
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05:02 PM
PFF
System Bot
chester Member
Posts: 4063 From: State of insanity...moved in and comfortably numb... Registered: Jun 2001
Shot some primer to see the imperfections. Still have a little ways to go..but you get the idea. When I made the plugs I made sure to use a piece of the scrap door skin that had a moulding clip hole in it to help support the moulding thats going to go across it.
Thats all for today, My hands are tired from sanding! Thanks for checking out my thread!
Rob D.
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The Dirty Rat Chopped, dropped and just plain NASTY! 383 Stroker MPFI with N2O 2.5" Drop 11" Brakes 17" Revolutions RCC Coilover Suspension Updated June 29 '03 www.dirtyratracing.org
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05:08 PM
GTFiero1 Member
Posts: 6508 From: Camden County NJ Registered: Sep 2001
Are you just using normal fiberglass and SMC-type (looks like duraglass) filler? I'm a bit surprised that you're not using a 2-part urethane-compatible epoxy (I've used ones from a number of different suppliers, but really liked the stuff from Dominion & SEM). Just curious as to whether or not you're concerned at all about using a less-flexible filler on an "enduraflex" body panel? (although I do understand that others have successfully used f'glass and normal fillers - just curious)
It's looking good! The 'Rat is going to be quite the head-turner when it's all said & done!
Chester when do you think your car will be ready? I guess you're going pop-doors? Should look pretty smooth like Archies. Are you going to use the same black door bumper material Archie used on the Stinger?
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09:31 PM
chester Member
Posts: 4063 From: State of insanity...moved in and comfortably numb... Registered: Jun 2001
Thanks for all the comments and kind words...Just so everyone knows - I'm a novice when it comes to body work. As a matter of fact - I hate doing it! But - I know what I want so here I am, learning as I go! Wait till my paint thread hits the forum! That will be another learning experience...
MinnGreenGT - To be honest I feel that the area where the door handles were is not that susceptible to flex. I did a sample fiberglass resin coat, about the thickness that I have on there now, on the spare panel and I'll tell you what - it bonds pretty damn good. I figure with the cloth it will be sufficient. Plus I already had the fiberglass and filler from another project.
Madcurl - When will it be done you ask? Completely? Hell, probably never! I hope to have the car fully painted and done for Wheatstock at the latest, but I'm trying my best to get most of it done before Daytona. I don't want to sound pessimistic but considering my work schedule, that might be too tall an order. I'm going to use the Mr. Gasket electric door release kit that I bought over a year ago! I'll have two hidden buttons as well as have it wired to my 6 channel (or is it 8, it's been so long since I've seen it) Alpine alarm system. I still need to shop around for some stainless poppers but that the least of my worries. Here's the kit that I'm using. I don't know what black bumper material your referring to that Archie used. The last I heard, the door handle area was fiberglassed in the stinger.
More progress tomorrow!
Thanks to all that have been following the thread. If you find this usefull, please feel free to rate me! (Shameless plug, I know!)
Rob D.
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The Dirty Rat Chopped, dropped and just plain NASTY! 383 Stroker MPFI with N2O 2.5" Drop 11" Brakes 17" Revolutions RCC Coilover Suspension Updated June 29 '03 www.dirtyratracing.org
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10:34 PM
chester Member
Posts: 4063 From: State of insanity...moved in and comfortably numb... Registered: Jun 2001
Looking real good Rob, I'll have to save this for when I start my shaving project. This was worth the wait even on a dial-up line, (I really miss my broadband when I am on the road)
Jonathan
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11:49 PM
PFF
System Bot
Dec 23rd, 2003
Matthian Member
Posts: 634 From: West Hempstead, NY, USA Registered: May 2003
I dont really understand all the fiberglass stuff, im not trying to come off as a jerk but i just dont understand what youre doing. Could someone explain it to me?
Whatever youre doing it looks like youre doing it pretty good tho
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12:19 AM
Master Tuner Akimoto Member
Posts: 2267 From: South Florida,USA Registered: Jul 2003
Looking good chester I just finished shaving all the moldings on my car but the handle still remains for now until I decide if i'll leave it that way.I will do a write up of how I did with pictures also will you ever consider how much money you have in that car?.
------------------ Tuners of the Quickest 4.9 12.51@118 mph
Rob, I'm curious as to how you're going to replace the door handle itself with the black trim. Will you cut up a trim piece and "splice" it in to the existing trim? I think that's what madcurl meant when he said "door bumper material"...
------------------ Mike...86 GT 4 Speed "Sucks to be me..."
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08:06 AM
Convertable Indy Member
Posts: 1644 From: Hanover, IN. Registered: Jun 2003
Rob, I'm curious as to how you're going to replace the door handle itself with the black trim. Will you cut up a trim piece and "splice" it in to the existing trim? I think that's what madcurl meant when he said "door bumper material"...
i was kind of wondering this too. seems like if you don't smooth out all the trim there's no use getting rid of the door handle since you need to put a piece in that will kind of look like the door handle anyway. will you try to bond the added piece to the stock ribbing and try to make it look like one smooth piece from door end to door end? that would make it better.
mine has kind of the opposite compromise to it. whoever did the work smoothed out all the trim but left the door handle, but it's pretty much sanded/flattened down (actually it kind of looks like it could be metal. i don't know) so it's about flush with the trimless body.
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08:49 AM
Philphine Member
Posts: 6136 From: louisville,ky. usa Registered: Feb 2000
I dont really understand all the fiberglass stuff, im not trying to come off as a jerk but i just dont understand what youre doing. Could someone explain it to me?
Whatever youre doing it looks like youre doing it pretty good tho
I'm "shaving" off the door handles.
Rob D.
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10:03 AM
PFF
System Bot
chester Member
Posts: 4063 From: State of insanity...moved in and comfortably numb... Registered: Jun 2001
Rob, I'm curious as to how you're going to replace the door handle itself with the black trim. Will you cut up a trim piece and "splice" it in to the existing trim? I think that's what madcurl meant when he said "door bumper material"...
Yes, I'm going to "splice" three sections of round moulding together to make it appear as one piece. It will mount and look like stock moulding all the way across, thats why the plugs I cut out from the scrap panel have a moulding clip hole in them, to help support it.
Rob D.
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The Dirty Rat Chopped, dropped and just plain NASTY! 383 Stroker MPFI with N2O 2.5" Drop 11" Brakes 17" Revolutions RCC Coilover Suspension Updated June 29 '03 www.dirtyratracing.org
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10:06 AM
TaurusThug Member
Posts: 4271 From: Simpsonville, SC Registered: Aug 2003
Originally posted by chester: I still need to shop around for some stainless poppers but that the least of my worries. Rob D.
Rob, I think you'll find that you will not need the 'door poppers'. I use a remote release and the tension of the window seal is enough to 'pop' the door open an inch or two. BTW, I have some stainless poppers(brand new) that are just sitting in my workshop! Sandy
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11:04 AM
Jan 1st, 2004
NotAFieroAnyLonger Member
Posts: 4413 From: 75762/Texas/USA Registered: Dec 2003
Chester, Looking GREAT bud ! Seems like you are doing just fine on your newly found hobbie of body work!!
If I may offer some advice.
You can use wax paper to help "smooth" bubbles out the fiberglass. the glass will not stick to it.
You are correct on the stress part of it. and using just the fiberglass will be fine. But I would use some of the bondo with glass in it to "finish" it up. Just rember that you will slam the door at some point and there might be some stress there. just don't put it on real thin.
As far as "popers", you can use an old trick of using a hood spring to "help" the door pop. Or go to www.autoloc.com they have a good line of products!
Be sure to build in a "back-up" system in case of dead battery
Thanks everyone!! I've been a little preoccupied driving the car around and attending to Elviras health...I should get back on this project within the next couple of days. I plan on making an external front decklid release hidden incase the battery goes dead.
Rob D.
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The Dirty Rat Chopped, dropped and just plain NASTY! 383 Stroker MPFI with N2O 2.5" Drop 11" Brakes 17" Revolutions RCC Coilover Suspension Updated June 29 '03 www.dirtyratracing.org
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10:05 PM
NotAFieroAnyLonger Member
Posts: 4413 From: 75762/Texas/USA Registered: Dec 2003
And Steve, (Smooth) how about you start a thread from this point forward on the completion of your not a fiero any longer?
JScott... Now we all know when I start a thread 9-10 time's it end's up in a war of some sort, so I'll pass. But, I will be showing some more of it and a few new 'redesigned' thing's I am contimplating on how to do it... LOL This will be spring though...
[This message has been edited by NotAFieroAnyLonger (edited 01-01-2004).]
That will be another learning experience...
