I've inherited a Fibergl*** Project and currently working on the doors as seen below. What material would be used to fill the "Gap" between the door frame and window gl*** channel? At first blush, I'm tempted to use "Expanding Foam" then shape with knife and cover with Fibergl***. Thoughts? Any and all advice from the pros are welcome.
It looks to me that you are missing the inner window trim that would surround the window opening on the inside of the door. I hope someone who knows more about this particular door can help you.
Expanding foam could be pretty powerful and distort the existing fibergl***. Also, fibergl*** resin melts most foams. You must use urethane foam. If you decide to do some gl*** work over a base I'd recommend doing a test piece to see if it's compatible with the resin. Wood and cardboard work.
I have the same issue with my doors! I purchased a kit for the gl*** to ride in, aka fuzzies. I plan to make a fibergl*** channel to mount the fuzzies in. What ever thickness I need will determine what size plywood I will use to make a buck to lay up the fibergl***. A light coat of Bondo on the edge of the buck and several coats of gloss paint, Krylon works great. Apply a few coats of wax or wax paper and fibergl*** around the edges to form a channel. Make the sides larger than needed. Let it set up, pop it off and final shape as required. You can gl*** it in the door or make metal mounts and screw it in. Install the fuzzies and go.
That looks to me like the door needs an inner panel to complete the channel and window frame area. All you have there is the outer skin, which needs to be completed. You could, with some effort, make a wood or MDF form and make the panels to complete the door. Or, if you don't want to do that, make a cardboard or MDF inner panel small enough to allow it to be skinned and just 'gl*** in place. It the top of the door needs additional structure to keep it's shape and withstand the gl*** going up and down against the stops, and stress from being slammed.
We had a local boat building supply store that sold all kinds of fibergl*** cloth, epoxies and resin, they also sold a fine powdered sawdust. You take the sawdust and mix it into your mixed resin to a peanut ****er consistency, spread it wherever you need it like spreading bondo to fill crevices. I used it on the t-bucket floor where the wood floor meets gl*** body almost 20 yrs ago and again on my truck about 5-6 yrs ago when making my own one piece tilt front filling a gap from fender to hood. Both pieces are still holding up great.
The product in question from the boat world is Cabosil, or you can also get micro balloons under several brands. You do not want to use foam. It both shrinks, and breaks down over time. Not an issue for most places we use it in boats, but bad for your application. Remember, resin has no inherent strength. It encapsulates the fibergl*** filaments. Resin and Cabosil is a good filler paste, and in some cases adhesive, but don’t be tempted to fill and use as the surface.
Thanks Junk, Appreciate the info. I had no real baseline to go from. But, it does seem as if a inner window trim is missing. Again, thanks.
34Phil, Great Question, Yes. but, hinge already made and installed on outside door. Again, great question
flynbrian48, I believe you are absolutely correct. Seems I'm missing the inner panel to complete the window frame area. thus, will require a board/form to complete the frame. Appreciate the insight!
I needed to install some fairly wide filler panels on my FG deuce roadster. I'm not sure where it was suggested but went to a local shop that does custom fibergl*** shower enclosures, they had some cutoffs from a job that worked great for me. I thought I had a better photo, anyway, they are shown in white gelcoat next to my ABS door panels, yes, the door panels are finished because it's a no frills hot rod.
Here's the trim that came with the kit. Doesn't look like the factory trim piece at all. But I think I can make it work and look like the other garnish moldings I already have trimmed to fit. I must lengthen the whole thing, and cut it to fit. This is nothing new for me. I bought a $3500 kit, what was I thinking? At least one buck will do both doors!!!
Douglas, you should check out his build thread. The guy is crafty and TIDY! Guess he's too modest to include it as a signature. https://www.jalopyjournal.com/forum/threads/gl***-32-5-window.1049484/
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