Today I started the process out cutting out the outer layer of skins. I only did the back side today to make sure I had a firm grasp on the process. Truthfully, if I am going to mess a side up, i'd rather it be the back. Fortunately, and this kills the drama, I didn't mess anything up!
Here you can see that I have most of the panels removed. These panels come out just like the dome and the inner skins......a hacksaw and a little WD-40. Once they're out, I take a file and get them nice and smooth.
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Here you can see my new table for holding parts!
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Here is a shot (another one) of how I remove the panels that I don't need. In this case, the inside part of the door. By placing a piece of wood underneath it, it raises the piece up a small bit, and helps with the removal. Simply place a chisel on the line, and give it one firm hit!
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Next,I take the pieces inside and match up the panels from the OUTER and INNER skin.
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Here you can see each inner panel resting on top of the outer panel.
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Next, it's time to place some JB WELD on the outer door panel. What I did, was place the doors on top of each other, drew a line with a sharpie along the edge of the doors, then put the JB right on that line.
PROTIP: JB Weld is MESSY! Especially for a first timer. I used a box of Alcohol Swabs to help clean up any runs that drifted into a spot that would be seen. These pads worked wonderfully!
Next up, it was time to clamp the piece together. I bought a package of 200 (YES 200!!!) at walmart for $8.00. This is how many I used on ONE piece.
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And finally, an hour later, I had all 6 panels JB Welded and clamped! They look phenomenal.
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In other news, despite my best efforts of holding off, I bit the bullet and purchased a JAG Aluminum Skirt today. There was nothing wrong with my MDF skirt, but I just had to get the aluminum one......!