Fiberglass half door project
 

Well...after taking my sweet time, I am ready to finish off my Blazer fiberglass half doors. I picked up these doors off of a fellow board member for a great price. I filled all the gaps and holes with fiberglass, then used two-part pour foam to fill the door core.

The polyurethan two-part pour foam works great for filling gaps and voids. I used the 8 lbs A-B foam from US Composites. You simply mix equal parts from each container and 45 seconds later, it begins to "cook".

Now I need to finish off the "flat part". I have sheets of ballistic kevlar that I cannabilized from one of my old police vests. Man that stuff is strong. I took one single thread of it and could not break it.

I was going to layer on the kevlar with epoxy resin and then skim coat it with bondo or gorilla hair. Them use an orbital sander to sand it smooth before paint. Any other ideas from body guys or gals??

Thanks...Rick

http://i913.photobucket.com/albums/a...5/DSCN9994.jpg
http://i913.photobucket.com/albums/a...5/DSCN9988.jpg

Re: Fiberglass half door project
 

Interesting. I'm interested how much does the foam help the rigidy. I did a test last year about if expandable foam helps stengthen piping used for transfer rolls. My findings where that the foam had no effect on the amount of weight a pipe could hold. The door skin is thinner that the pipe wall so it will help its just a matter of how much.


Its a really cool concept I can't wait to see the finished product. I always wanted to have a round tube A-frame for a door.

Re: Fiberglass half door project
 

I like the idea.

Orig. idea looked SICK!

http://upload.wikimedia.org/wikipedi...t-SSII-big.png

Re: Fiberglass half door project
 

They used to make them like on that Scout back in the day. My brother and I test drove a first gen Blazer with door openings like that in the late 80's.

Re: Fiberglass half door project
 

I think that foam holds moisture, so it may cause the door to rust from the inside out... I hope I'm wrong but you might want to look into it...

Re: Fiberglass half door project
 

It will look like what Bobby posted on the Scout. I still need help on using fiberglass mat, cloth, or kevlar. Momma bought me an air sander for fathers day and I'll use that to make sure that the glass and filler is sanded down perfect.

As to moisture, the doors are also fiberglass and will be totally sealed so no moiture or humidity will get in.


I'll post more as I go.

Re: Fiberglass half door project
 

Sorry... I missed the title where it said fiberglass doors.... didnt even know they were available in fiberglass....