az_gila
Well Known Member
How should I fix an error?
Apparently during the bonding of my first door some of the cabosil goop was probably smeared off the area shown in the sketch -
The missing bonding showed up when I attached the door hinges and can be verified with a bright light shining through the door skins - I have the early green glass parts. The periphery of the door is good and the unbonded area is only on one location. It is probably has less than a 1/32 gap but it does show up when the hinge attach screws are tightened.
I can think of two options but I'm sure there are more.
1. Drill a hole (#30?) in one side in the center of the 4 screw holes and inject a medium mix of flox forcing it to go out in all directions. Use nylon screws on the existing holes to prevent leakage.
2. Cut out on one door skin (the outer?) in the shape of the the square shown in the pic above with 45 degree edges. Fill with cabosil and/or flox and re-attach. Use nylon screws to ensure alignment and tighten them down to ensure 'squish'.
Possible problems I can see -
1. Getting the right consistency and being able to force the epoxy mixture into the gap.
2. Getting the cut-out piece back into alignment, but this may be solved with a custom shim. It looks like my door assembly needs a .025 or .032 shim under the outer door hing anyway.
Any other options? It's only fiberglass so it can be fixed.
It is getting that good gull-wing look though -
Apparently during the bonding of my first door some of the cabosil goop was probably smeared off the area shown in the sketch -
The missing bonding showed up when I attached the door hinges and can be verified with a bright light shining through the door skins - I have the early green glass parts. The periphery of the door is good and the unbonded area is only on one location. It is probably has less than a 1/32 gap but it does show up when the hinge attach screws are tightened.
I can think of two options but I'm sure there are more.
1. Drill a hole (#30?) in one side in the center of the 4 screw holes and inject a medium mix of flox forcing it to go out in all directions. Use nylon screws on the existing holes to prevent leakage.
2. Cut out on one door skin (the outer?) in the shape of the the square shown in the pic above with 45 degree edges. Fill with cabosil and/or flox and re-attach. Use nylon screws to ensure alignment and tighten them down to ensure 'squish'.
Possible problems I can see -
1. Getting the right consistency and being able to force the epoxy mixture into the gap.
2. Getting the cut-out piece back into alignment, but this may be solved with a custom shim. It looks like my door assembly needs a .025 or .032 shim under the outer door hing anyway.
Any other options? It's only fiberglass so it can be fixed.
It is getting that good gull-wing look though -
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