Here we go, some more boring work in progress pictures. BTW, the glass weighed in at 15lbs and the regulators and associated hardware are 12lbs. If the beam is 24 lbs...that's 51 lbs per door. 102 lbs total on both doors. That's frigging amazing.
Hard to see here, but I'm trying to point out the spot-welds. This end (latch end) proved to be difficult. Holes didn't look so neat, no pictures of that. If I end up giving up on cutting the beam in half, the latch end might get opened up. I'll cover the hole with fiberglass most likely. Or rivet in some sheet metal I have laying around.
Here I am cutting the door beam in half. My 3" wheel isn't deep enough to reach the channel on the skin side. Might cut a notch out that will let me get at that channel. Or I'll just cut a hole in the door as mentioned before. I will also be cutting out some structure of the door since I won't be using regulators anymore.
Also, you will notice I changed to using my Iphone 4 for pictures. Not going to use my $5,000 setup anymore. Especially with metal shavings flying about.