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Old 18th October 2021, 17:26
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Mister Towed Mister Towed is offline
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Thanks Paul, yes, I'm afraid I too found the adverts more interesting than the show...

So, progress over the weekend and today revolved around continuing to develop the racing doors.

I reused the alloy former that I made to create the sills to make a front/lower inner section for the passenger door, then glassed it into the door with a gap of three lolly sticks (5mm) all round to ensure it would still open and close without jamming -





Slots added to take the hinges -



I made the door inner quite thin so it would be flexible enough to align properly - it's about three layers of 200gsm mat - and I expected to have to reinforce it later, but now it's glassed in place it's really very rigid. That will only improve when I join the back of it to the rear of the door so I reckon it's strong enough. I'll be doing that this week once I've decided how I want it to look. Although I have an idea in my head as to how it's all going to come together, I am making this up as I go along!

As I've never had much faith in limit straps to stop the doors opening too far and damaging the bodywork, I wanted to fit proper stays. I had to guess what might work and sourced a pair of Peugeot 206 rear door stays brand new for £15.00 on ebay.

I went for the rear ones as they're longer than the fronts and I guessed, correctly as it happens, that would give me more scope to make them fit and work.

They're obviously designed for much heavier doors than I have and the 'ramps' on them were too steep to operate smoothly without jamming, so I trimmed them down with the angle grinder.

They're also about 1cm too long, which is fine as it means that the front stays would be about 2cm too short so the door wouldn't open far enough if I'd bought a pair of those, and I just ground in a new 'stop' so they don't allow the door to over-extend. Hopefully these pictures should explain better than I've just tried to -

Before



After



Doing its job



And the spring clamp inside the door



Tomorrow I'll be doing the same to the driver's door, then I need to join up the lower and rear sections of the doors where there's still a gap and finish them off by creating inner panels to box the doors in.

More later
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