molding sides in

[Xeks]

pics of sides we are currently working on this weekend

[CougarBalla2k5]

Nice!! Now I got some idea of your fiberglassing skills! Very kool.

[ND4SPD]

best decision you could have made man

[Xeks]

sorry for the fuzzy pics, its an old digital camera. doesnt do very well in low light.
but the sides are coming along nicely and the rear is about done as well.
soon its headed to the paint shop =D

[StreetConcepts]

before glassing the skirts on did you use any kind of an epoxy based panel bonding adhesive? The reason I ask is that I do this work regularly and by just fiberglassing the door jams you'll likely end up cracking.

I bond the skirts on first with Fusor #147 allow 24 hrs to cure and outgas.

Also rather than using fiberglass mat or cloth I used milled glass fibers mixed with resin to blend the door jam. I first drill small holes into the metal so that the fiberglass filler I made drips down in and once cured it's almost like a weld. After I rough sand the milled glass fiber filler I smooth it out with a lightweight filler.

If you have any questions feel free to ask.

[Xeks]

yea i used 3M panel bonding adhesive to glue the sides on first. then 3M seam filler for the top of the sides in front and rear of the door. after that i glassed in the jams. you can still see some of the screw holes from the screws that held the kit on tight while the adhesive dried in a couple of the pics so far.

[StreetConcepts]

yeah that 3m adhesive works well. The only problem I ever had with it was when frenching the door handles it tends to expand in the heat more than tthe fusor does. The 3m caused the handles to ghost out badly on a cougar I did. I'm redoing the handles and this time will grind a grove into the seam and glass that and overlap the seap with cloth.

You're doing a good job. It's nice to see someone doing their own work. When you are done you can appreciate the amount of work that went into it.

[ZEXCougar]

You are doing a great job so far! Did the sides fit ok, or did you have to cut them at all to make them fit?

[Xeks]

the sides dont fit at all until you cut them. but i think the problem with other people's sides not fitting right is they or their body shop didnt cut enough and tried to push the kit into the jamb and screw/rivet it down making the door drag on the kit when opened or closed.

[StreetConcepts]

yeah the door jams of the cougar don't allow for much thickness. are you molding the rear or doing any other custom body work?