I went ahead and got to work on some of the bodywork bits over the last few days. I removed my leaking wing and glassed in and smoothed the mounting holes. No more leaking trunk! Will start mocking up the lip spoiler at some point soon.
I also pulled the quarter window scoops to take care of the horrible blindspot they create as well as to paint them a gloss black.
To start I used the thin cardboard from a soda case to layout the shape I wanted the windows. I used the thin material so it would follow the curve of the material better and allow me to feel where the shape was for marking and cutting.
Once I had my shape fine tuned I added some masking tape to the scoops themselves so I could trace the cutouts onto them.
Next I used a 1/16" drill bit to make many small holes along my inside corners. I then slowed the drill speed to allow me to "saw" the material between each hole with the bit.
Once I had the corners cut, I used a rotary tool (off brand dremel) with cut off wheels to cut my lines. On the fiberglass scoops I cut to the "inside" of the lines. When I cut the plexiglass/acrylic windows I cut the "outside" of the line. This will allow me to force fit the window into the scoop. With the flexible nature of the acrylic and the bonding panel adhesive I plan to use it should make the "window" curve like the scoop so I don't have to heat form the "window" to shape.
Laying out the windows with my pattern.
All the pieces, old and new, waiting for me to mix some resin.
Taping the side of the scoop cutout and the outside so that any escaping resin can't bond.
I next covered the inside of the pieces I cut off with foil tape so I could use them to build the lip I plan to glue the window to. Once done I duct taped them in place back on the scoops.
Next came mixing up some fiberglass resin and beginning to build up the lip with resin and mat.
I was only able to get one glassed tonight but will finish it and the other tomorrow with more images to follow. Once done I will trim and sand the lip to size and go ahead and smooth all the visible glass and mat for priming and painting. both the inside and visible outside of these should look smooth and deep black glass before I add in the windows and they are ready to go back on the car.
Day 2 progress
Started by glassing in the second window ledge. What I learned from working on the other yesterday made this one go much smoother.
By tearing the mat rather than cutting it, the edges smooth in and bond with the existing piece better.
Once I had the second scoop laid up and the resin was curing, i was able to get to work on pulling the "window" clear of the scoop. What this doesn't show is the rather large pain in the butt this was to pull. I had done a poor job of material control yesterday so I ended up having to cut a channel all the way around the inside of the window with my rotary tool so I could get the piece to pop out like it was supposed to.
I did a much better job laying up the mat and controlling the flow of resin today so the second window was about one-tenth the difficulty to pop free as the first one.
A closer look at both ledges. Both will need trimmed in and some filling work before I will be happy with them.
The ledges will end up cut down to either 1/4" or 3/8" roughly. With the panel bonding adhesive that should be more than enough to make a solid bond that will hold up to the wind.
I will keep adding onto this post as I work more on these and get ready to piece them together.
This resin is far less opaque than what I usually use so it is hard to tell how thick my lay-up is from just looking at it. As a result both of these ended up a bit over buiit for a simple window ledge
