After popping my door panel off the alloy former and tidying it up a bit I'm not happy with the result. It looks 'okay' but my efforts to create a chamfered edge using hose and plasticine resulted in a slightly uneven opening that was a bit bigger than I intended -
Plan B has, therefore, swung into place, which is to create a flat panel with greater thickness around where the opening will be so I can carefully cut it out and shape it how I want it -
Again, that's curing in the garage overnight as the cold snap we had here today has slowed down the hardening process somewhat
