Made some more progress on the door sill over the weekend.
Here it is layed up in fiberglass. The resin is still wet. I've used vinyl ester resin and some light weight chop strand mat. The thinner mat folds around the corners easier and is better for complex shapes. There are 3 layers on the side and 5 on the top.
I've ground back the gell coat on the edge of the door opening so the new glass has a good surface to bond too.
Once the resin had gone off I trimmed the overhang. This is easer to do when the resin is still a bit green and hasn't fully hardenend. You can just use a hand held hacksaw blade, easy.
The Vinyl Ester resin is quite dark when it's wet and lightens up as it goes off.
Now the filling and sanding to smooth it all out. I started with a coat of glass reinforced filler to square up the edges. It's stronger than the regular filler so should hold up to impacts better. I also worked on filling and smoothing out the door jam area. Hopefully when painted and trimmed it'll look tidy.
It's dusty work so keep the vaccum cleaner and a small sweeping brush near by and clean up as you go.
All smoothed out and ready for a coat of spray polyester.
Cheers