December 11, 2003

Jack is removing the rest of the mustard paint from the roof.
This is the last picture you'll see of the old painted hood.

Remember, paint is weight. It's hard to see, but the scale says 12 lbs. When we're done repainting
and doing the detail glass work on the underside, we'll hope that we're around 11 lbs.
I grind the mustard paint with 36 grit first.

Then, I sand the rest of the paint with 80 grit using the D.A. sander (dual action). When one side is done, I'll do the other. Sanding this hood took about six hours. I could grind it with 24 grit in an hour, but it would ruin the original gel coat silver surface. We want to keep all the original silver gel coat in tact on the entire car.

Remember when we found the two holes for the leather straps that hold the hood down on the windshield wiper apron? Here are two pictures of the mating holes on the hood.

After the roll bar was installed, we had to re-glass the inner roof structure to the roof. Jack has done a more than stellar job replacing the parts. Next, Jack will sand the chipped and tired textured coating from the cockpit. The marks on the tape tell us where the edge of the coating starts and stops.

You can see the texture was applied around the seats. In most 904's, the complete cockpit was textured. To save some weight, 906-001 only got it where you could see it.

The reason the cockpit was sprayed with this texture was because the surface of the part when it is removed from the mold has imperfections and pinholes. The texture covers this and gives it a more uniform look.

As you can see, the texture is missing in many spots. We will sand the cockpit completely smooth and re-texture using our guidelines.

The cockpit is so thin it's more translucent than the normal 904.
Jack will start to sand the paint off the doors.

The white area is primer under the mustard paint. You can clearly see three round dimples. This is where the light is mounted that illuminates the number on the door. This light was used at LeMans so we will put the original light back in position.

Door on, door off, paint off.

Door on, paint off.

This is the mechanism for the pull-up window. Only the destined to be six cylinder model 904's & 906 prototypes had these pull-up windows. The little black metal object in the picture on the right is a factory trick. Down the Mulsanne at speed, the door wants to open. Undoubtedly, one of the drivers complained of this problem so this part was invented...when the door is closed, the little flap goes up under the roof and keeps the door closed.

These are shots of the original detail. You can see that masking was not the forte of the gentleman who painted this car mustard yellow.

Some of the mounting holes are worn out. We will repair them, remove the old texture and re-texture the doors to match the cockpit.

More detail shots of the doors. The hinges are aluminum and the hinge pins are actually plastic (weight, weight, weight). The picture on the right shows body filler protruding the three holes that hold the I.D.light on the door. When we see things like this, we think it's exciting.

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