Finished resin coating the package shelf. Sanded the driver's side speaker mount. The resin could probably stand another day. Took a less aggressive approach to covering the panel clips on the kick panels. It worked OK. I might add two more layers tomorrow to assure they don't telegraph.
Attempted two variations of a method to glass the edge. Neither worked very well. The bubbles will have to be ground out and patches put in tomorrow.
The package shelf went much better. The fleece was stretched over the rings and stapled in place. The shelf as put back in the car and fastened down. As the resin sets, the package shelf should ''lock in'' to the correct shape. Resin was applied and the openings were cut out.
The perimeters of the braces were marked off on the driver's side kick panel. I then sat in the driver's seat and determined the best angle which would allow for leg room and aim. 1/4'' dowels were cut so the ring would be 1-3/4'' raised at the back side. The dimensions were then transferred to the passenger's side panel.
The holes were located and cut. The rings were hot glued in place.
The funnel for my sandblaster was the perfect diameter to mark off the approximate OD of the fleece ''cone.'' The fleece was then stretched and stapled.
In order for the panel to take the shape of the car, originally 5 screws were used to hold the back edge of the panel to the car structure. The top three were replaced with interior panel clips and the screw holes in the A pillar were enlarged to 1/4''. The bottom hole would not allow room to use the interior clip. Then next hole up would have caused interference with the hinge, so it was abandoned. You can see how on the passenger's side it was tried. The bottom screw in photo 5 is only temporary, holding the panel to shape as the resin sets.
Yet to do. One more layer of fiberglass to the back edge to reinforce the interior panel clip holes. Then Bondo and primer.
The 6 x 9 rings were positioned and hot glued in place with 3/16'' dowels. Holes needed to be cut in the luan plywood and the metal. A test fit with the seat back, seat belts, and one speaker gives a hint as to how this is all going to look when done. I'm happy.
The kick panels were started. Before starting, however, big blobs of Liquid Nails had to be scraped off. A mess.
Only one pattern was needed. The right side was cut first. The left side had to have the pattern changed slightly due to a ''bulge'' at the top of the inner panel which allows for e-brake handle mount. I think they both will need to be clamped in place and then dampened in order to better fit the contours.
A paper template of the package shelf was taped together, marked, and cut out.
The package shelf kicks up at the back. A scrap piece of fiberglass panel from the trailer ceiling was used since it had a straight edge and was handy. The measurement was transferred to the luan plywood.
To facilitate the bend in the plywood, a cut was made through 2-1/2 of the 3 layers. A test piece was run to verify the procedure would actually work.
After final trimming, two metal tabs were cut out of 26 ga. coated steel, bent to shape, and epoxied to the package shelf so the front could be secured to the body with 2 screws per tab. The bend received a fiberglass strip to help hold the angle.