Wow, you guys were right about these doors

[MB750]

They are WAY off. The trunk and hood were pretty good to go. I'll need to do some sanding and trimming, but I was able to make them both work without any thing yet. The doors needed my belt sander immediately. When I finally got the drivers side the lower forward corner is sunk about 1/8" below the body where everywhere else it's flush. Now the passenger side was giving me fits up by the dash. It's as if that door has too much curve at the top of the door.

I ordered some fiberglass chopped strand mat and a roller, I've already got a bunch of epoxy from my dashboard project. I'd rather bulk it up with that than bondo.

[Jeff Kleiner]

...It's as if that door has too much curve at the top of the door.
I ordered some fiberglass chopped strand mat and a roller, I've already got a bunch of epoxy from my dashboard project. I'd rather bulk it up with that than bondo.

The curve of the body and door don't match on either side (that's one of the things addressed with the Mk5 body revisions). For the sunken corner of the driver's side door place a thick washer between the door and hinge on the lower forward stud. When you crank it down tight it'll spring the steel frame inside and help bring the sunken corner out. Make that corner flush with hinge adjustment and the lower rear corner will be out from the body but you take care of that by pulling the body outward in front of the rear wheel. I'd advise against epoxy. These bodies are made using vinylester...not a good idea to mix dissimilar materials. I get vinylester resin from US Composites

https://www.uscomposites.com/polyesters.html

Jeff

[MB750]

Thanks for the tips Jeff, and the link. That's the best price I could find, and they're almost in my back yard. Order placed.

[GoDadGo]

Yep, The Doors & Gaps Were A Pain In The Neck!

https://youtu.be/6QXWP5H8mT0

https://youtu.be/6UK6K2jcwTU

https://youtu.be/po1Bb2_XDDk

https://youtu.be/iwslgKJUaKc

Just Know That You'll Be Victorious In The End!

[MB750]

Yep, The Doors & Gaps Were A Pain In The Neck!

https://youtu.be/6QXWP5H8mT0

https://youtu.be/6UK6K2jcwTU

https://youtu.be/po1Bb2_XDDk

https://youtu.be/iwslgKJUaKc

Just Know That You'll Be Victorious In The End!

I'm gonna split the door like you did. I like that idea.

[GoDadGo]

I'm gonna split the door like you did. I like that idea.

I used Evercoat Fibertech product on the upper areas of the door where they meet the cowl by the dash.
I also used Fibertech to back fill the door before I glassed over the split.
Wooden deconstructed cloths pins were used as wedges.
Evercoat Rage Gold was used to smooth things out.
Hope this helps and I wish you good luck.

Evercoat Fiber Filled Video:
https://youtu.be/JwAErvc2tN4

[MB750]

I used Evercoat Fibertech product on the upper areas of the door where they meet the cowl by the dash.
I also used Fibertech to back fill the door before I glassed over the split.
Wooden deconstructed cloths pins were used as wedges.
Evercoat Rage Gold was used to smooth things out.
Hope this helps and I wish you good luck.

Evercoat Fiber Filled Video:
https://youtu.be/JwAErvc2tN4

That Fibertech looks like Bondo that's impregnated with kevlar "and other high tech fibers" according to their website. It's a neat idea. I've done that before with shredded fiberglass and epoxy to strengthen up my wife's broken hair brush.

Yes, I'm kinda cheap sometimes. To me, fixing something broken is more fun than just buying a new one.

In fact, there's a Youtube channel called Tech Ingredients where this fella does all manner of crazy stuff, but all of it is entirely based on science and physics. Here's the video I'm referencing:



Edit: Wrong video at first. This is the correct one.

[GoDadGo]

Here is a website (Youtube) that will give you all sorts of great techniques when glassing.

https://www.youtube.com/@FishBumpTV

You can even book a fishing charter trip with him if you want to catch a few flounders.