One of the
problems that has been dogging me is how to close the gap from the
window to the roof line. Unlike the real car that has the weather seal
that sits on top of the window, I'm looking for something cosmetic.
The real ones the window rolls down when the door is activated to
allow the window to clear the roof. My solution is to put a weather
seal strip against the window to give the illusion of a seal. This
would not hold water out but since I am not taking it out in the rain,
this will at least serve that purpose.
I used a 1/2" aluminum angle iron
that was screwed to the roof. I should have used shorter screws as it
went through the top and I will have to refinish and paint it again.
Next, I fastened belt weather stripping from JC Whitney, part #
81ZX9751A using trim adhesive. When the door comes down, it rests
against the edge of the weather seal and closes the gap.
I finished
installing the mirrors. This consisted of making a plate out of ABS
that was heated and formed to the triangular section where the mirrors
mount. Next I cut the Fiero mirror plate to fit the motor. Depending
on how the mirror motors are mounted, you will have to adjust. I
sealed the area around the wires and the mirror with silicon. I fed
the wires through the door and connected and tested the functionality.
I bolted the mirror through the access hole in the door. This would
have been much easier with the doors off. I used some Butyl window
tape and silicon on the mirror housing to fasten the mirror. I seated
the mirror and taped it in position overnight. Repeat for the
passengers side.
Once the
mirrors were in place, I needed to cover the access hole. I made a
template out of paper then cut some FRB board to the correct shape.
Drilled 1/4" holes and placed upholstery fasteners through the FRB. I
then covered with padding and vinyl. I fastened in place and the
access holes are now covered.
One of the challenges in
running the wires from the interior of the door to the inside of the
car. I elected to route the wire along the hinge. This will prevent
any stretching of the wire loom. I have temporarily fastened with wire
ties but plan on using a more secure method when completed.
Fabricated a bracket to
hold the solenoid as well as the door release cable. This assembly will
be bondoed and glassed to the interior door panel. The bracket was
bondoed and glassed to the door. I also used wire ties that were
fastened to the inner door panel to hold the wires from solenoid to the
front of the door. I then installed foil backed insulation on the
interior of the door by gluing it to the door panel. The solenoid and
cables were connected and the wires fastened with wire ties to the door
interior.
To fasten the
panel to the door, I used a combination of hidden fasteners and
stainless steel button head screws. The hidden fasteners I purchased
from JC Whitney. I drilled holes in the door itself to make sure I was
not hitting a screw that held the door frame. I then ground a bolt to
a point and put a nut on it and inserted it into the hole. By placing
the panel on the door and pressing down, it would mark the location on
the panel that I would need to drill the hole for the fastener. I had
pulled back the leather and inserted the fasteners through and
carefully repeated the process for all 4 fasteners. I then glued the
leather over the inserted fasteners with contact cement.
I drilled a hole
through the door frame and welded a 1/4" bolt that I would fasten an L
bracket to. I bondoed and glassed this bracket in place to the door
panel. This allowed a secure connection from the panel to the door
frame to take the stress of pulling the door closed. I fabricated a
bracket that was bolted to the door opener and the cable connection.
The bicycle cable was wire tied to the bracket and the cable was
fastened to the handle. There is enough slack in the cable that the
door panel can be lifted off the door and removed if necessary.
To cover the speakers
on the inside, I had a suggestion from a viewer to use a cool whip
container and velcro to fasten to the inner door panel. Because I
needed access through the speaker opening to bolt the panel to the
frame, I could not permanently fasten the speaker cover. Once the
panel is bolted in place, (be sure to put the cover in the door
first), it was simply pulled into place and the velcro secured it in
place. It was necessary to notch the back edge to clear the cable.
Once the panel was
fastened, the door was put in place, shock connected, speaker cover
put in place and speakers added.
To install the weather
stripping on the outside of the window, I pop riveted it to the door.
I then used 1 1/2 aluminum carpet trim cut to shape to cover the
rivets. I still need to paint the strips and glue them to the door but
it will ad a nice finish.
I purchased some the
speakers for the stereo system and the cables for connecting. Still
need to get an amp.
Started on the
interior door handle. I inserted the handle through the interior panel
and made a U bracket to hold it in. I will be using a bicycle cable to
connect to the actual door release mechanism. I fabricated a bracket
that will be bondoed and glassed to the inside of the door panel. This
holds the cable steady when the door handle is pulled. The cable will
actually be strapped to the bracket with wire ties when it is finally
installed.
I marked the speaker
location to make sure it cleared the door mechanism on the inside. I
marked off the area on the door with masking tape so the leather would
not be scuffed by the saw. After cutting out the hole I fitted the
outer ring on the speaker and screwed the assembly to the door. The
grill snaps into the ring. I set the door panel on the door to see how
it will look. I'm still working on a way to fasten the door panel to
the door without actually using screws on the outside.
I needed to fill in
the front edge of the door to match the body. I covered the primed
surface with waxed paper and masking tape. It turned out pretty good.
Still need to do the primer.
Got glass in both
doors now. Still need to do bit of minor tweeking on Drivers side. I
will be glad to get these behind me. Small things that when you narrow
the door, you end up with space issues for clearance. When you don't
listen to your own advice, the frame get twisted. I hope the small
crack on the bottom edge of the glass will not grow any longer.
Worked on the mirrors.
To fasten them, I drilled a hole in each leg large enough to accept
the head of a 1/4" bolt. I then cut a slot to either side. Using 90
minute epoxy, I secured the bolts to the inside of the mirror legs.
After they were set, I filled in the gaps with bondo. I drilled a hole
through leg into the cavity and inserted the mirror motor into the
mirror case. I then marked the door to accept the bolts and a hole
for the mirror wires to go through the door.
The
drivers door had to be fixed to align it properly. When the gas shock
was not installed, the alignment was fine, but under pressure, the
bottom edge of the door was about 3/4" outside the body edge. I
attempted to reposition the frame inside the door but nothing worked
to my satisfaction. My solution was to cut a slice from the inner
door, clamp it together and then use a temporary plate to hold it in
place. I then glassed the two pieces together inside the door, applied
bondo to the outside and now it aligns perfectly under pressure.
I installed rubber
seals on each side that the roof actually rests on. Just about
finished with roof.
I crated the brackets to hold the roof receivers. First I drilled hole
to accept the posts. I then fabricated "T" shaped brackets that would
hold the latch assembly. These were bondoed in and later glassed in. I
used 2" tube to align over the latches. I welded small tabs on the
tubes and then bondoed them in place. I also had to redo my third
brake light holder for final fit.
I replaced the original receivers with the new style that swivel. It
was necessary to grind out the original location. I welded small tabs
on the receiver fitted the roof with a spacer to simulate the weather
seal and then bondoed them in.
How to stretch a roof
in four easy steps. When I spliced in the new roof line and modified
the receiver, I found I was about 5/8" short. I cut a slice off of the
roof and then using paint sticks and masking tape, I aligned the
pieces. I used Glass mat and cloth as well as dowels between the tow
pieces to close the gap. Finish with bondo and you are all done. I
will need to do slight mods to the center brake light so the roof will
seal properly.
I added an additional
support to the window post to add additional stability. I am in the
process of grinding the fiberglass away from the tube steel installed
by IFG so I can add an additional plate. All is welded now and I also
added a support from the dash to the cross member to make the side a
little stronger
Iinstalled braces from the firewall to a support for
the door striker for each door. This will support the striker as well
as give me some additional side protection.
.I worked more on the
mirrors. The mirrors have an impression where the motor goes. Check to
see that when themirror
motor is positioned that the control pivits are verticle and
horizontal. Next cut out the opening, and drill a hole in the top leg
to accept the wires from the motor.
The
parts consist of the plate on the that will be attached onthe
inside of the door, the latch mechanism, plate, cable opener and
striker that is attached to the door Once
the latch is assembled, the by pulling on the cable, the lever
opens the striker plate and release the door.
Now
cut an opening in the door that will allow the latch
mechanism
to fit through.
Trial
fit the plate. It will then be necessary to drill three additional
holes through the plate and the door. You will have to cuntersink the
holes and then fasten with the 1/4" stainless bolts with flat washers
and lock nuts on the inside. Do not put them too close to the edge or
the bolts will tilt as you try to tighten them because of the
curvature of the fiberglass on the inside.
Finished
plate
I
added two 1/4" bolts through the bottom two holes. I also added a
plate on the inside for the bolts to go through to add some additional
strength to prevent any twist at the hinge plate.
The striker pin is installed through the fiberglass with theplate on the
backside. I will fasten the strike plate to reinforcing when the body
is permanently mounted.
Create
a loop with cable through the latch cable. Drill a hole in a washer to
attach to the door latch. Use cable crimpers
to close the loop. I found the cable
crimps and special crimpers at a fishing supply store.