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07-04-2014 07:17 AM Kick Panels / Package Shelf
Spent a good portion of the morning (July 3) building a chicken run for the garden so my hopes of primer by the end of the day went away.

I started by adding two more layers of cloth over the panel clip holes. That makes four layers. I think that should be sufficient.

Bondo, sand, repeat. It looks so easy when other people do it. I am close on the package shelf. The right kick panel will probably need two more rounds and that means three for the left one. Time to get started.


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  [Entry #568]

07-02-2014 10:16 PM Package Shelf
Sanded all of the package shelf. Mixed two batches of filler and applied. Sanded. What did I learn. Mix smaller batches. Try a little less catalyst. Hope to have the package shelf in primer and the kick panels ready for primer by end of day tomorrow.


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  [Entry #567]

06-30-2014 09:00 PM Kick Panels / Package Shelf
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.


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  [Entry #566]

06-29-2014 10:07 PM Kick Panels / Package Shelf
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.


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  [Entry #565]

06-29-2014 06:48 AM Kick Panels
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.


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  [Entry #564]

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