FG door panels 03 cavalier 4-door

Hey, I started a project on st patty's day, this is what I have done so far, enjoy. I'll keep updates a comin. Constructive criticism, praises and even flames are welcome!

That's me makin sure the camera works hehe

Gettin ready for wrapping.

Twins... Actually it was pretty difficult making sure they were even

And the wrapping begins...

Gettin tighter

and then... no and then.... and then... no and then

handle and lock spot cut and wrapped

I had to make the pod slope down to flat on the door panel or it would bump the dash when it is put back on and then the door wouldn't be able to close. Staples worked good.

And the first coat of resin. It's kinda cold outside so it took it like 4 hours to harden. I just let it sit over night because it got late. I plan on adding 1 more coat of just resin to stiffen things up a little more, and then come in with some weave mat and more resin. You guys think I should pop it off of the original door, or just leave it on? I'm not real sure how it is going to hold.    Please all the suggestions you guys have, feel free to post.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

much thanks to the mods for fixing all my mistakes! I should have updated pics in a couple hours.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Looking good man. I like the way you did your handle cut-outs. Can't wait to see how this comes along.

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The night's as hot as hell. It's a lousy room in a lousy part of a lousy town - I'm staring at a goddess...

Goldie. She says her name is Goldie.

I almost got my first layer of mat completed. I am mixing my resin kinda hot becuase it is only 50 degrees out, and it is hard to time it right to where I don't waste any. I will have pics by tonight though.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

NEW PICS, nothin special just my first layer of glass.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Ok, I don't know what I am doin wrong... pics are at these links

https://home.insightbb.com/~sdp/PICT1271.JPG

https://home.insightbb.com/~sdp/PICT1272.JPG

https://home.insightbb.com/~sdp/PICT1273.JPG

https://home.insightbb.com/~sdp/PICT1274.JPG

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Looks good , Now your about to get the fun part the filler , what kinda filler are you using off hand ?

LMAO, I like the humor in this thread. Looks good so far...I hope you use some Rage Gold on these doors, if not, its gonna be HOURS of sanding for you!!

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Im a fiberglass whore!!

I am going to be using bondoglass for some spots on the handle and arm rest that I need to fill in,  Then I planned on using bondo just because it's cheap.  But if it really makes a difference I might run down to autozone and get some rage gold.  What's the price difference, anyone know offhand?

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

you would have made your life easier using Mat instead of cloth...plus for this type of piece it is considerably stronger..adding extra resin orve an already cured piece will do nothing but add weight to it...and increase the chances of it cracking your finish..

torn pieces or mat will blend together considerably better then cut cloth ever could...but anyway what you have so far looks good...

just a couple tips for the finishing...when you coat it with filler...i personally prefer Rage gold..simply for sanding purposes..but there are other light weight fillers out there, "Bondo Brand" has a gold series filler that works well too..Rage gold is only a couple dollars more expensive then the other stuff..

as for finishing...and filling...you should mix yourself a nice runny MILKSHAKE batch of filler...

MilkShake is made by mixing 2:1 resin to filler and the appropriate amounts of thier associated hardeners possibly a drop or two less of the hardener just to give you a little time to spread the whole piece...since it is cold were you are working it may not matter how much hardener you use...just use the appropriate amount.. the resulting solution will have a milkshake like consistancy..using a flexible puddy knife spread this over everything about 2mm thick, possibly slightly thicker where you can see very obvious low spots..( IE where the Staples are) and dont worry this stuff will get ridiculously hard...

from there you will want to catch it in what is called a Clay Phase...where it isnt quite hard but not tacky to the touch...using a heavy grit paper or file you will be able to rip the stuff down very easily..if you leave it to cure...it wont be fun to sand...besure to allow it to cure before doing final sanding/ the majority of the sanding though...only catch it in the clay phase to knock off all the very high spots..the rest should be done after it has cured..

Bondo glass (Kitty Hair) is not necessary for door panels unless you plan on removing it from the door and inserting it by itself, without the factory anel behind it...if you really want to use it, there again thin it out with regular resin 2:1, so it will spread easier..the stuff is retarded thick, and doesnt spread very well or sanded fiberglass panels otherwise..

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Fiberglass Guru.

hey thanks for the tips cougar, I think I will go with the milkshake.   It got colder here so I probably won't be able to work on this or update pics for about a week.  I am going to wait until it gets at least 40 out.  Friday it is supposed to warm up into the upper 40's so I will continue then.  As for it not being as strong I am going to put on about 2 more layers of the cloth.  Do you still think it won't be very strong after 3 layers?  I just hate working with mat.  It would be better if I could get some better paint brushes, but I am working on a budget. 

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Honestly i find mat considerably easier to work with because you dont get seems...like you do when you over lap the cloth...

a couple layers is a good idea because these doors will inevitably get kicked and hit by stuff...2 - 3 layers will be more then enough..

the crappier the brushes the better they are..the ones i get at walmart are plastic handle with plastic bristles...they are stiff and they work great.sometimes i even cut 1/2 or so off the bristles so they are even more stiff....and they are dirt cheap..dont use the foam brushes by any means...

you will find that those flood lamps work wonders for fiberglass..everyone has one of those kicking around..if not a small space heater workes well too..

i would be careful building up the edges of the panel too much, as you said you will run into clearance issues..

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Fiberglass Guru.

well imma grab some mat then and go from there, i will post more pics soon. And I know exactly the brushes you are talkin about, i figured they would be too cheap, but i'll givem a shot. I used a floodlamp inside one time and it worked good, but I completely forgot about it until now, I'll hafta break that bitch out and use it again. Also, i think I am going to add some more staples to areas I don't think will stay put, what do you think about that?

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

I was also going to recomend rage gold ..

You will hear nothing but good stuff about it ..

Ed

it isn't like canadian or anything is it?  I can get it at autozone in the US?

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Im pretty sure you can find it in the US....The Autozone's around here dont carry it.....Your local Autozone might carry it thought....If not I know they carry Bondo Brand Gold Filler....its not as good as the Rage but it works....By the way the progect looks like its coming along great, good luck.....

god resin sucks when it is 39 degrees out!

is there any way to thin it out, or should I just wait until it is warmer out?

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Wait till it is warmer or find somewhere that it is warmer, garage with a heater.

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Certified Security Specialist
Always check info with a digital multimeter.
I promise to be good.
Tell Darwin I sent you.

I've been sick lately, sorry I won't be on much.

OMG mat is so much stronger than cloth. I have only done really small fiberglass projects before this, so I didn't even realize it, but I put a layer of mat on one section of that door and it is strong is hell. It barely even flexes. And it didn't even seem to build up much thicker. Oh yeah and I can't even tell where once piece starts and the other ends. I will send you pictures as soon as I get the whole door panel covered with it, but I do have to wait til it is warmer like auex said, becuase I dont' have a space heater.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

ok i got a couple layers of cloth on and now I slapped some bondo on her and here is a picture of it partially sanded down.



lots more sanding to do.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

hey man keep this updated cuz I might just scrap my project of added kickpods to my door and go with a whole new design considering I have a 94 Suzuki Sidekick and the panel is basically a piece of 1/8" wood with plastic and a handle to close the door with. . . lol I am liking what you have done so far, keep it up man lookin good!!!

well thanks for all the compliments everyone. I haven't updated lately because I finally got a job and they are workin me about 60 hours a week. So I don't really have time to do much else except relax... but it pays pretty good so I will have funding to continue the project no problem. Once overtime dies down I should have some updated pix for ya. Prolly in about a week I should get 2 days off.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

looking good are you goind to paint the door panel or are you going to wrap it?

still kinda tryin to decide... if I am gonna wrap them I am about done with sandin hehe. That's a huge plus. I was thinkin about going gloss black... right now my car is pretty much stock. I have done a custom headliner, but I am willing to redo it. It is black vinyl right now. I don't know really I am still thinking it over

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Thin resin with styrene...Works great at wicking through mat or cloth

I thought styrene was foam?

Also I think i have decided to wrap these in white vinyl. I have some swatches coming in I will post pictures of whenever they get here and I'll want everyone's opinions.


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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

I don't know what playr is talking about with the styrene and fiberglass but styrene is just another plastic.

When they take styrene and inject it with pentane gas bubbles they make styrofoam...is that what you're thinking of sprawl?

Ummm I didn't know they use pentane gas... or that styrofoam was just another kind of plastic with bubbles in it, but now that I think about it that makes a lot of sense. I think i kinda just put two and two together in my head and though.... styrene / styrofoam and then kinda figured they came from the same thing or somethin. I dunno, sometimes I just make doodie up too.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Hey I just got my swatches in and I think I am going to go ahead and go with the bright white vinyl. I dunno there is just something that gets me off about something that bright and clean and smooth and sexy and caressable... well you get my point. here are some pictures of it. It was hard to get how white it is to come out right in the picture. I put it next to an offwhite swatch I got in the last picture and you can tell. I tried different settings on the camera too.









Click on thems for supasizeded pitures nickel

sorry ebonic moment

and I thought I would give ya guys a pic of the car so you know what i'm workin with here. I need the bumper painted. It is just in white primer right now and I haven't got the side skirts in yet. And it needs rims and a drop.

they aren't the best pictures right now, I will post a 5.0mp version of it so you can see the texture as soon as my ftp site comes back up.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Hey, a lil update, my vinyl comes today and I put a chevy symbol in the door that my crossovers are going to sit inside check it out, click on them for ginormous pics.


And look at this huge bluegill! He is inside a cooler lid, i wish i would have remembered to weigh him before i ate his fatass.


and this is how many we caught. All of them over 8 inches or else we throw them back. Lots of good eatin there. Either me or my wife caught this many like 4 days in a row. Our freezer is stuffed with lots of tasty fishes.





EDIT 1:

I GOTS MY VINYL!

I just want to take a moment to recommend denverfabrics.com to everyone for vinyl/suede/other fabric projects. I have ordered from them twice now and each time they have shipped within the next day and have had a superior quality product. I dont know if anyone else has ordered from them before, but they should!   Here is a linky if anyone wants to check them out. They give you two extra inches for every yard you order, they only charge like 2 bucks for every swatch and then they give you 2 bucks off your order. They are just really customer oriented and a pleasure to do business with. And their prices are unbeatable.

Here is what they gave me! Click on them for bigger pics.



White vinyl yeayeah






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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

what is a swatch?

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Hustle, Loyalty, Respect

it is a sample of the fabric.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

okies, here is a picture of the vinyl wrapping it. Still some work to do on it. I need to fix the handle part of the door and I need to put the black windowtrim back on the top. And there is going to be a black trim on the chevy symbol. And I am going to put some Soundstream xstream 6.5's in them. Anyone got any opinions on those? I'll put a picture of them too, I won't be using the grills, just the woofers and then the crossovers will be visible inside the chevy symbol and will be lit with green led's. Ok here's the pics anyways.





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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

Look really nice along with some good eats on those sun fish.

what are you gonna do with those spider grills?

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I shall never outrun my guardian angel - again.

sendin them your way if that's why you are askin. If not they will go in the garbage. But you would just have to pay shipping and that's it.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!

looks really good have you thought about maybe some neon lights behind the door panel to illuminated the emblem?

that looks really nice, good job

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hey thanks for the comments everyone, and yeah I am doin green led's with the crossovers behind that chevy sign. should be sexy.

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fiberglass reminds me of peanut brittle... but fiberglass tastes better!