962 recreation with a GT3 Heart...
Discussion
In all seriousness by the time you're finished with this body work it's going to be such a patchwork of quality areas you have 'corrected' and original surely you're going to build molds to a) avoid doing it again b) lay up a nice new clive shell uncompromised by the original? I dare say after this project you will have a few customers wanting at least replica bodywork if not complete cars! Normally I'd never dream of suggesting it given the amount of work involved but given how quick you work I'm thinking molds would be about a 20 minute job 
Well after some head scratching yet again out with the grinder.. If it ain't right then I'm not happy..
The inner and outer skins of the door just would not straighten out enough, so I cut of the outer completely
allowing me to rebuild the outer from scratch and straighten the inner and reinforce it from the inside.
As you can see from the state of the original glass work it was way to thick and the 2 parts of the door where not put together with much care and attention. Once the major lumps had been ground off so the inner panel was back to almost flat it actually corrected half the bend (Surprise surprise), but once we pushed it out 2mm past flat (allowing so it can spring back a little once the brace was removed) I added 3 layers of glass and some core matt to give it an even and strong thickness now.
Outer skin just as easy to build new again with the same process as the rectification we use on the side pods, cut off the curved top piece and grind to a knife edge then laminate up a new with added core mat of course...
Also while doing these little bits I've been removing the original Catch holes for the front and rear clip, cutting out the large recesses and laminated them back to flat, so I can flush mount the newer and nicer billet "Aero 3" catches we have.
Gelcoat then layers of matt to fill the holes left...
The inner and outer skins of the door just would not straighten out enough, so I cut of the outer completely
allowing me to rebuild the outer from scratch and straighten the inner and reinforce it from the inside.
As you can see from the state of the original glass work it was way to thick and the 2 parts of the door where not put together with much care and attention. Once the major lumps had been ground off so the inner panel was back to almost flat it actually corrected half the bend (Surprise surprise), but once we pushed it out 2mm past flat (allowing so it can spring back a little once the brace was removed) I added 3 layers of glass and some core matt to give it an even and strong thickness now.
Outer skin just as easy to build new again with the same process as the rectification we use on the side pods, cut off the curved top piece and grind to a knife edge then laminate up a new with added core mat of course...
Also while doing these little bits I've been removing the original Catch holes for the front and rear clip, cutting out the large recesses and laminated them back to flat, so I can flush mount the newer and nicer billet "Aero 3" catches we have.
Gelcoat then layers of matt to fill the holes left...
Edited by GTRCLIVE on Tuesday 19th January 22:25
Clive. Mind boggling stuff. I wouldn't know where to start making corrections like this. As a matter of interest though. How good were the bodies of the real cars? Are you going to end up with something better than the real thing?
Also could your panels be used on the original? There must be some (admittedly small) market for replacement parts. The great thing is you could probably charge what you like.
Also could your panels be used on the original? There must be some (admittedly small) market for replacement parts. The great thing is you could probably charge what you like.
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