I just binge read this entire thread in one sitting and all I can say is, "WOW!" You are quite talented with some mad skills and are not afraid to tackle anything. I would have to consider you a "Jack of All Trades. Master of ALL!"

I can definitely appreciate the amount of time and effort you have put into every detail of what you do, Sasquatch and the Classy Ford. My hat's off to you sir!

I'm looking forward to the next progress update. :thumbsup:

Thanks guys - appreciate the kind words.

Beginning the door panels with a fiberglass base. Started with 1/4" plywood screwed down tight so it replicates the shape of the door as it curves in both directions. This will be a make-shift mold, will get removed and discarded. Painted blue as dark colors help with seeing air bubbles while laying up the 'glass.
Attachment 79132

Masked off, 3 coats of release wax and 2 coats of PVA mold release.
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2 layers of 1.5oz mat over the entire panel with an additional 3" wide strip of 1.5 oz. around the edges for some extra rigidity. Vinylester resin.

Lots more to come.
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Let them cure overnight and pulled out of the car, trimmed the 'glass. Plywood(blue) discarded.
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Panel clips installed. Now the fun begins!
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Looking great John. What area of Boise are you in? Looks like you might be using an RV garage as a shop, or do you have a dedicated shop building?

Hi Jody - Thanks! Live in an area called Hidden Springs, about 15 min from downtown Boise, you in town? coming over to help sand? Beer frig is stocked.
I built a shop next to my house back in 2013, has worked out pretty well except it could be bigger!
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That looks awesome! Wife and I will be there tomorrow. Have a list of houses to look at and make sure we still like the area. We're putting our house up for sale, cannot afford California any more.

I currently have 4.33 acres and two small shops. The smaller one is 1200 s.f. and mainly used for equipment storage (tractor, sweeper truck, mowers, etc.) The one next to it is 1400 s.f. which works fine for me and a buddy, but could always use more space. I'm trying to determine if I can make an RV garage work. Gives me the height for a lift (which is a requirement), but square footage is a lot smaller than what I currently have. Ideally I'd have enough property to have a separate shop, but we're also trying to stay on a budget. I found a perfect place for me, but the wife doesn't like the interior of the house lol.

This is my current setup.

Good luck on your house hunting.

Thanks Wayne.

Jody, you do know it gets cold in Idaho, right? They also have this white stuff called snow that falls from the sky during the winter. It's a form of what we call rain which is water falling from the sky.

Only kidding. I've been to Idaho one time on my way to Yellowstone and found it gorgeous. Would love to visit again. Not sure I could tolerate the snow enough to live there though. The mountains and evergreens though, wow! Good luck house hunting.

John, glad to see you back on the car. I love seeing the process you go through to make all these parts. Keep up the great work and thanks for sharing.

we upgraded when we moved from the Puget Sound

the shop (60x64) and house
https://i.imgur.com/4wvyjMo.jpg

and had money left over for upgrades.... best of all, I see the sun on a regular basis (which wasn't true in Seattle).
we were aiming for Idaho - near Spokane, but the deal and my wife's employer came along and this was simply too good to pass up....

I promise there is a plan here! I know it looks rough right now, ok really rough!, but it's just the process. Lot's of goal posts to kick between here most notably, trying to keep getting in and out (not to be confused with in-n-out) as easy as possible with the door bars. Blending those speakers to the kick panel sounded like a cool idea but they are right in line with with your feet as they swing out so they will likely get kicked a bit, sorta knew it was a problem but no choice so it's inked. And positioning the door pull and door lever so they clear the bars and don't pinch your fingers but still work for closing and opening the door. And keeping some level of cool design. And these doors are double concaved so keeping the panel tight to the door is important. Hot glue and scrap wood are your friend - Ha!.
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Nice


Sent from my iPhone using Tapatalk

No doubt you'll figure it out, and it will be killer just like the rest of the interior.

Looks good John. People just don’t see what you’re envisioning. We will, I’m sure it will be stellar like rest or the build.

How do you like your Milwaukee cordless drill? Is it a brushless one? How’s the battery life? I’ve been eyeballing them , LOL.

Keep up the great work.
Jimbo

Looks like its going to be killer. So much talent.

Just binge read this entire thread. Amazing work and thanks for sharing the fine details and explanations! The truck as well is a piece of art, would love to see more of it.

Beautiful house/shop setup by the way.

Hi John, first glad your wife is okay, that's a scary thing. Do they work through a body module or just power and wiring?

Glad your wife is ok buddy.

Family first even the MIL. Glad you all are ok and hope you had a good holiday season.

Thanks guys! All good, yep.. scary time for sure.
Wayne - just power and wiring no other interaction with any modules or computers. Piece of cake.

Glad to hear she’s doing ok.

Went through the same with my wife last year, except it was confirmed as cancer. Caught it very early and after treatment she's doing great. I'm very happy things turned out good John. :thumbsup:

Thanks Wayne! Glad your wife won! Hope everyone here is encouraging the women in their lives to keep up on those tests. Seems we both have early detection to thank.

Thanks again everyone for the well wishes!

I didn't go a great job of documenting the process here, frankly I changed my plans about a gazillion times so it wouldn't have made sense anyway. I will take better pics during the passenger side.

I think it came out pretty good and solved the problems at hand. Couldn't completely solve the problem of your feet clipping the panel (near the speaker) when you are getting out, getting over the door bar and pulling your leg in tight with the supports on the seat is just tough. Maybe I need to take some yoga and limber up!
I know it looks like a lot of body filler but the bulk of shape was created with florist foam and then a thin layer of fiberglass cloth, then a sweep of filler. Panel is actually fairly lightweight.
Attachment 79653

I will blend the upper plastic panel into the lower here, still to come.
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Tried to carry the arm rest such that it followed the door bars, not really to hide them but just made sense to the eye. These two pieces are removable and actually pretty complicated hollow parts. I'll get some pics during construction on the pass side.
Attachment 79655

I don't like the way the arm rest cuts off the speaker but I couldn't get around this, made a couple of attempts but they just didn't look right. I am going to make a lower flange on the speaker grill right about the arm rest so it appears the cut off circle was purposeful. It's gonna mean some work on the press to reshape the speaker grill.
Attachment 79656

The door pull is bolted to the door so it not only is sturdy for closing the door but also serves to pull the door panel in tight.
There will be an separate insert panel here. Plan for now is leather on the entire door panel with the insert being either carbon or alcantara.
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This is the plug for the lower dash panel. I'll mold this when I do the molds for the dash and then make fiberglass parts. The headlight switch and the mirror control will go in this panel.
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Amazing things going on here!

Don

Some filler primer so it's all in one color. Will make a few adjustments but this is close. The company that I got the door pulls stopped making them, only had blue ones left, they'll get re-anodized later once I choose interior colors.

Attachment 79666
Will blend the plastic upper panel into the lower next.
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Looks really good. I like them!!

The level of talent you possess is mind boggling!

The flow is spot on IMO. Way to bring vision to life my friend. :trophy-1302:

Those door panels look fantastic.

Gauges arrived.
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Started the passenger side. Had to lower the mechanism. I'm using 69' Camaro mechanisms with the Lokar cable pull and the Ringbros lever. Steve Lenning (Carbon Camaro) gave me the mechanisms about a million years ago!
Had to open up the inner door structure in a few places to make room for the cable and mechanism so I added a few reinforcements so the door pull would still be solid.
Also ran the cable through a couple little setups of a teflon bushing anchored with an Adel clamp.
Attachment 79761

The Lokar cable pull comes with a pulley. It all comes together very well and is a solid and super smooth open.
Attachment 79762

Now the fun begins, foam and fiberglass! The MDF ring is just a spacer to space out the door panel to make room for the speaker and speaker grill. Will make sense in later pics.
Attachment 79763

120mph speedo?
I think someone underestimated this rocketship. Lol

LOL. I’m sure he’ll never go over the speed limit. LOL

WHAT gauges are those? SpeedHut ??? Those look great.