So I finally got back to the fiberglass doors. The ones I imported from USA were too light and flimsy and would not accommodate the windows without flexing creating issues with door closure and secure closure.
So I stripped them down by removing the outer skin from the inner shell frame.
I completely rebuilt a new inner shell frame with structural fiberglass woven mesh and added extra reinforcing to the window mechanism mount points and quarter window mount points. I also added extra structural mesh to the hinge and door latch mount points.
Then to stiffen the frame I added an extra layer of structural woven mesh.
All of this has allowed a structure that can carry the windows and door mechanisms without sagging.
The extra structure also makes the door much safer. Also much heavier.
I also fitted the steel hinge reinforcing panels that I fabricated earlier and fibre glassed these in. It made a huge difference to the door structure combined with the extra structural fiberglass.
So after this cures I will start fitting the inner shell to the hinges with the door rubber fitted and door latch on. When this fits correctly then the outer skin can be fitted to complete the door.
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