October 15, 2004

Andy is about to cut the rear window out, remember we left it whole to give the firewall strength while it was being attached to the car.

Now Andy is gluing in the headlights. We use epoxy cabosil for this application.

Andy and Jack have finished fitting the factory original brake ducts. Even Porsche had to do bodywork to get them to look and fit decent. I primed them red when they were on the bench because it's hard to get primer or paint in the back of the ducts after they're installed.

The finished product looks great. The other picture is the windshield surround being attached to the windshield frame (chassis windshield hoop).

Now the door sills are being attached to the rest of the body.

While this process takes place, we put a straight edge along the edge of the body to assure a straight line between the nose and the tail.

The lower weather strip panel is glued in after the door sill is installed.

The car is still pretty light. Here, the boys are moving it from the flat board to the saw horses. This is because the bottom of the car is completely attached to the frame.

The car just bit Jack, so Jack slapped it to get even!

Fitting the door to the door frame is a hair raising experience because the fit is so important.

The fit is important because you don't want to use a lot of body filler to make the edges flush. The reason is because the doors are so flimsy that any extra weight really distorts the fit. On this car we will use the original Gull wing door type hinges (original 906) on the passenger door. On the drivers door we will use hinges so the door opens forward. The factory updated many 906's with the forward hinging drivers door.

To fit the door, you must tape it in place where the two glass panels fit the best. The next step is to cut the edge of the doors so they're maybe 1/2 inch longer on each edge.

Then, the skin is removed and 2 inch tape is used to mark the edge of the opening (on rear apron and front fender).

I then place the door back on the body and tape right on top of the existing tape. Not only does it hold the door down, but it gives me a perfect mark where I need to cut the edge of the door. Remember, if you lay the door on top of the body it's hard to get a mark on the inside because of the door frame. When the edge of the door is sanded, I glue the skin to the frame with epoxy cabosil. When I glue the drivers door together, I'll show more detail between the frame and the skin. I know this is a little tough to understand, but you can fit any Porsche prototype door this way and get a perfect fit without killing yourself.

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