October 15, 2004
about to cut the rear window out, remember we left it whole
to give the firewall strength while it was being attached
to the car.
is gluing in the headlights. We use epoxy cabosil for this
Jack have finished fitting the factory original brake ducts.
Even Porsche had to do bodywork to get them to look and fit
decent. I primed them red when they were on the bench because
it's hard to get primer or paint in the back of the ducts
after they're installed.
product looks great. The other picture is the windshield surround
being attached to the windshield frame (chassis windshield
door sills are being attached to the rest of the body.
this process takes place, we put a straight edge along the
edge of the body to assure a straight line between the nose
and the tail.
weather strip panel is glued in after the door sill is installed.
is still pretty light. Here, the boys are moving it from the
flat board to the saw horses. This is because the bottom of
the car is completely attached to the frame.
just bit Jack, so Jack slapped it to get even!
the door to the door frame is a hair raising experience because
the fit is so important.
is important because you don't want to use a lot of body filler
to make the edges flush. The reason is because the doors are
so flimsy that any extra weight really distorts the fit. On
this car we will use the original Gull wing door type hinges
(original 906) on the passenger door. On the drivers door
we will use hinges so the door opens forward. The factory
updated many 906's with the forward hinging drivers door.
the door, you must tape it in place where the two glass panels
fit the best. The next step is to cut the edge of the doors
so they're maybe 1/2 inch longer on each edge.
the skin is removed and 2 inch tape is used to mark the edge
of the opening (on rear apron and front fender).
place the door back on the body and tape right on top of the
existing tape. Not only does it hold the door down, but it
gives me a perfect mark where I need to cut the edge of the
door. Remember, if you lay the door on top of the body it's
hard to get a mark on the inside because of the door frame.
When the edge of the door is sanded, I glue the skin to the
frame with epoxy cabosil. When I glue the drivers door together,
I'll show more detail between the frame and the skin. I know
this is a little tough to understand, but you can fit any
Porsche prototype door this way and get a perfect fit without
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