A small progress update. Sanding is pretty tedious but I'm slowly getting there.
I've been working on fiberglass repairs and a few body mods. As noted previously the CR body's lack of a decent door sill is a bit annoying. A few guys have successfully built their own sills with great results. I thought I'd doccument my go at it.
Fingers crossed it works or I'm going to liik like a bit of an idiot (More than usual anyway).
The first step was welding in the support beam between the dash hoop and the door pillar.
Next step is to build a skeleton to lay the fiberglass on. I've used a foam I bought from the fiberglass supply. This stuff is resistent to the chemicals in the resin and doesn't break down. I reckon it's the same stuff Dale has used. A $13 sheet will be more than enough to do both sills and have spare for mistakes.
Here's the foam cut to shape and glued in place. I just used some of the same vinyl ester resin as used in the layup mixed with some microspheres to bulk it up a little bit.
Next once the resin has gone off you can shape it. It cuts really easy with a hacksaw blade and you can sand it to shape. There were a few gaps left so a thin wipe of body filler smothed them out.
I've also ground off the gellcoat along the edge of the body to expose the glass underneath and roughened it up. This will give a good surface for the resin to bond to when I lay the fiberglass. The last thin I want is the new glass delaminating from the body after I've painted it.
It was too cold in the shed last night to start laying fiberglass. Hopefully it'll be a bit warmer this weekend.
Cheers