Fiberglass Car Door Construction - Step by Step Details

Finally here's the detailed video of how I've made these doors - better, stronger, faster...
I estimate it took me about 200 hours of working, testing, thinking, re-doing to make the first door frame on the passenger side. There's ALOT of stuff to consider when putting a car door together from scratch!
I then replicated the process for the driver's side door, which you'll see here step by step. I do go back and forth between the sides to show various elements, but both doors are as identical as I could make them (except for the fact that the actual door opening widths are off by 1/2" to begin with!)
I estimate the time to make the second door was about 25 hours.

[@jeffhamilton6856]

Thanks! This is exactly what I was looking for. I'm looking at a kit car that I really like but I won't be able to get in and out without doors. Keep up the great work!

[@juanrafaeltosado1812]

!! GREAT JOB!!!.

[@diversity2739]

Thanks

[@khaledzaitoun7321]

Beautiful 👍

[@BillsBuildandRace]

I appreciate your time & workmanship, so am not having a go at you. But putting all that steel back in the door, and then the minimal weight difference between just the skin of a door in thin metal cf. fiberglass - well I can't really see what all your long hours really gained you. What I do by way of comparison, is I mold the inner door frame in fiberglass, taking in the hinge & lock mounts, but only three inches of the door's inside edge that faces the driver. When I copy that and then glue it to the outer skin my doors weigh 7kg compared to the factory 28kg, and the door just bolts straight in place. But you sure put some effort into this.

[@Stoneface_Garage]

Bill, nice to hear from you. I'm a big fan of your channel and have learned a lot from you about fiberglass fabrication. I am not concerned about weight, only stiffness. This is a road car, not a race car, and will have real glass and power winders. As the door is frameless, I need to ensure the window is adjustable and closes tightly every time. That means a stiff hinge, frame and latch to mount it on. The door shell (and entire car) I started with was very old and flimsy fiberglass; check out the rest of my videos! I haven't weighed the doors yet, but I guess they're well under 20 lbs. Thanks again and keep offering suggestions!

[@BillsBuildandRace]

@@Stoneface_Garage Road car... now what you did makes sense. My fault for being totally "race" oriented. That explains why you put those winder mechanisms in your doors. What is the car btw... a fiberglass kit car of some sort?

[@Stoneface_Garage]

Victress coupe, rare kit from the 50's actually. See my channel home page and video for more info.

[@rdannyb]

Very nice. Subscribed

[@Stoneface_Garage]

Thanks and welcome

[@amyslingsby6947]

Is Tucker exhausted because the chipmunks are out and he’s been busy chasing them?

[@Stoneface_Garage]

No, he's an old hound dog and always sleeps 18 hours a day!

[@messaoudena.rahman3899]

معلومات زكام الله يحفظك.

[@Stoneface_Garage]

Thanks, I think...