Well the Jaguar doors turn up so I took off the door skin to see what was involved in making up a frame which would locate the runners, glass, and motor mechanism and also to see how it would fit to my door beams. The frame is made of 16x16x1.5mm box. I had to cut off the top brackets on the runners and make some new ones because I wanted the top box to also act as the bump stop for the window mechanism (Also has a small cam for fine adjustment). The next stage will be to fit it to the door beams.
Now I have the both headlight casings finished and in position I then needed to make up the wirer headlight surrounds for the buck. The former will be used to form the wire to shape of the headlight case and also to position the wire surround in the buck. So I cut a wire former out of 10mm plate and then bolted it to a face plate so that I could heat the wire up to temperature and wrap it around the former. The next stage was to set up the jig cross members at the required angle so that I could use a piece of 30x30x3 box section to bolt the former to and then hang the box from the jig cross members, for the other side it was just a case flipping the former and box over and re-bolting them together for the opposite hand.
I needed to change the front wires which ran from the bonnet/grill to the wheel arches because they finished to low on the wheel arch and they just did not flow right. So the new wires start in the same place on the bonnet/grill but finish at the top of the wheel arch. I have also made up the other headlight case and finished off the spoiler.
I needed to make two bucks for the inner headlight case because of the design but I have made it so the two parts inter lock when fit into the metal case (they will also be bonded in when I have decide on the final colour). Since a lot of cars using projector lights do not use a reflective inner case I decided to play around with different colours of styrene sheet. After forming a couple of sets I decided to try out the silver grey since I think this would go well with a white car which is the favour of the month at the moment.