Fiberglass Repair Advice Please

[edwardb]

Getting down to some final details on my Gen 3 Coupe build before paint. I'm fitting the Factory Five window kit and deciding I'm not happy with the mis-match between the straight windows and the curved edge of the doors. I've seen a couple in person, and seems typical and the solution is to put a cushion or gasket of some kind along the door edge. That would work but there's not a lot of contact area on either the door or the window and seems to me straightening the door edge would be the better choice. Especially since I'm at a stage where that's possible. The max gap is about 1/4-inch on the DS, and 5/16-inch on the PS. I'd like to build up the edge to make the door edge straight and close the gap. I suspect the windows will be left on most of the time, so the edge would be relatively protected. But I don't know that for sure. Either way it needs to be strong and also not picture through to the paint. Looking for suggestions. Don't pretend to be an expert about this at all.

I've done some searching and watched some videos. Seems I need to taper back on the top and bottom so there's something to grip plus reduce the chance of a line showing through. That's easy enough and assume I need to remove the gel coat near the joint anyway. I'm thinking I would put some tape or whatever on the window and use as a mold for the edge. Then some foam or gasket or whatever along the bottom to create a dam. Then fill the edge and coat/recoat/sand as needed to blend. I have some vinyl ester resin and chopped glass. That's one choice although I admit don't particularly like to work with that stuff. I also have 3M HSRF, which I've had great luck with would like to use unless someone has a better suggestion. Worried though this might be too large a gap to fill that way. Looking for some expert opinions here. Thanks in advance.

Driver side. About 1/4-inch max gap.


Passenger side. About 5/16-inch max gap.