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.
Attachment 79133

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.
Attachment 79134

Let them cure overnight and pulled out of the car, trimmed the 'glass. Plywood(blue) discarded.
Attachment 79144

Panel clips installed. Now the fun begins!
Attachment 79145

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!
Attachment 79147

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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....