[Goosesdad]

IT GETS WORSE BEFORE IT GETS BETTER!! The seemingly chaotic approach here - makes me laugh too.

The foam for the speaker cover was mostly carved to shape and then covered with drywall mud in order to smooth to the final shape. This is still wet, sanding to come tomorrow, then I'll show how it gets glass'd and then how the foam and drywall mud gets removed.

The center section for the insert has the 1/2 round molding glued down and first sweep of filler laid down.

The rear foam is shaped and will be covered with glass, today. The wood was recessed a bit so the glass would have somewhere to anchor. Given the door panel is concaved front to rear and top to bottom, both this rear glass'd area and the front speaker area, actually add rigidity and keep the shape of panel once it's all cured. You can sort of see the horizontal relieve cuts in the plywood in the rear, that plywood is not only for the esthetic looks as it adds some dimension but it's epoxied to the flimsy fiberglass panel so it holds the vertical concave. If you go back a few posts, you'll see the scab'd on blocks that helped me clamp this in place tight against the door while the epoxy dried.

Lots of goal posts to kick between here (maneuvering around the roll-bar) while trying to make it flow and look right. And trying to keep it as light as possible.