As luck would have it, this top
section of the door panel didn't fit like the other side so when I trimmed the foam from the
sides, I left this section a little heavy. The foam now follows the contour
of the door which was easier than adding fiberglass. The distance of the
overhang is only 1/4" so I don't think
it will look bad once it's covered with material or be hard to work with. This section will
also be
covered by about half of the window frame which will help in supporting
it. I'll have to be careful when it comes time to cover it as the edge
will want to fold over.
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This is the section that will have the
other color which is just below the middle of the door. It's curved and
is bigger on the right than on the left. I used a razor blade to do the
cutting and this foam would dull the blade with just one cut (from one side
to the other). I found out that holding the blade at a slight angle
wasn't a good thing either as I had to come back and trim the edges square. I
also found out that I needed to cut from one side to the other in
"one" cut. I started in the middle of this panel and worked toward myself so
I didn't have to lean way over but I also found out that when the two cuts
came together in the middle, they didn't match like I wanted. The second
panel was done in "one" cut and the blade was held square which
came out much better.
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Here is the piece that I cut out from
the above picture. I'm getting ready to glue on a piece of 1/8"
thick wood paneling which will give me something to fasten too (like the
headliner bowtie). I'll be leaving this large for now and then after the
material is on the door panel, I can then fit this piece.
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One thing I had to do was cut a small relief
in the wood for the metal clip that holds the door panel on. I used my
Dremel to do this which worked great.
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