Fiberglass half door project

[Rick212]

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