I’ve been working on the first (passenger side) body side panel, the second (driver’s side) panel, and the tailgate forms all at the same time. So, rather than an individual blog post for each one here is an update for all three.
Here the glass cloth is added to the second panel.
Here is the first fill coat.
And the final fill coat is on.
Then the process of leveling the surface and polishing starts.
After that, the second layer of ash trim goes on.
Before microwave steam bending the curved parts I increase the curvature of the bending forms. The curves were close last time but a little more curvature will help.
The parts bend nicely.
When routing the round overs I went past my stop line (just like last time). So it’s time for another patch.
After the center strip is glued on the panel can be lifted from the forms.
And I can start cleaning up the back side for the eventual addition of fiberglass cloth.
Meanwhile, I keep trimming the outside edges of the first panel.
With the edges trimmed, sanded and polished I then add a coat of epoxy. I also add epoxy to all the inside edges of the trim. Those edges had some gaps where the bonding coat did not fully squeeze out.
Once the epoxy cures I the sand and polish all those surfaces – again.
At this point I can cut the panel into 3 pieces. The part in front of the door is cut free. This cut is the shortest one so I start here. This piece will be cut in two later as the tip goes on the hood.
Here’s what the cross section looks like. This will eventually be sanded, epoxied, sanded and polished. Sorry the focus isn’t better.
Next the piece behind the door is cut free.
While this is going on I get the CNC going to cut the tailgate forms.
And get the body forms off the strong back.
I now have a clean strong back and a set of tailgate forms.
The notch on the right side of this picture shows where the panel extends toward the bottom of the tailgate. It also helps me keep from turning one of them around. They are almost symmetrical (but not quite).
The detail work, that being the precision required on not just the work piece, but also the forms with the precise shape, placement, & alignment, is phenomenal. Fantastic work Steve.
Thanks for the comments! Lazyman - yes the back side has fiberglass on it as well Splinter - I measured ten times and cut once. My cut line is in the middle of the door gaps which will be ~1/4" so I have room to adjust.
