Cool, I love those willy's, almost bought one a few years back. If I get energetic enough to do another kit car type build, it will be a top contender. I don't have much weight or mass to contend with on my T doors. I did build the steel stiffeners that are fore and aft of the door openings that serve as body mounts, stiffeners, jambs, and they will be encased with the oak in glass. The oak is overkill, but it will serve as a stiffener for the actual door as well as a strong mounting surface to hold the hinge and latch fasteners. I am second guessing my decision to use a chunk of old barn oak because it is so dense and hard, old growth oak, but I had it, so I used it...two band saw blades and a couple belt sander belts later, I think it's good. I plan on using foam to fill the void on the inside of the doors and glassing them smooth. They are small enough that I think it will look ok. I ended up just ordering mill finish cast steel hinges from speedway and a very simple surface mount latch. I was going to install bear claw style, but after much thought, don't feel the extra work and money is merited for such small, light doors. I can retro them in later if I change my mind. I think I have it worked out. I have the oak cut to fit the inside contour, have the preliminary glass work done to the tub to fill the voids in the door contour and create a nice surface. I just don't know if the glass will be strong enough as a stop alone, or if I should make a steel reinforcement to attach to the inside of the jambs and laminate into the glass. I am still up in the air about exactly where the bottom of the door will be. My floor ended up terminating about 1/2" or so below the door body line, which I may or may not just grind off and have a smooth side, but I need to think it through. I don't know if I want a lip at the door bottom, or cut it so the floor is the actual bottom door stop. Although I would have to cut through the glass that I just finished to attach the floor to the tub, I think I like that idea best. It's likely no more actual glass work and I think the end result will be better. The big wild card is that I filled the void between the top and bottom of the plywood substrate with fibered bondo when I glassed it to the tub, so it will be a chore cutting it without massacring it, cut off wheel, I think will work. In retro thought, I wish I had installed a piece of aluminum duct tape to that area, it would have made the chore easier. Mine is much simpler than yours. I don't have near the patience or skill set with glass that you demonstrate. I would have to do a lot more of it to get the nuances and techniques down, but it is a cool craft. Most of my experience with it via the body shop was in repairs, boat repairs, etc. the process of creating stuff is a whole new ball game. I like it. It is a chore keeping things clamped, etc so they won't distort as they cure. I had a time with my floor, and it was real simple and flat. The bulkhead, or firewall was a treat also, but someone cut it out decades ago and it was distorted, I had to cut a substrate, rout it so it flush fit the original flange, and rout the other side to accept the steel inner reinforcement. It turned out perfect, but it wasnt by chance. I had to clamp and brace the day lights out of it. Glad I did it, the body is so much stronger and more rigid. Yea, it gained some weight, but the longer safer life is worth the trade off in my mind. I can still lift it on and off of the frame alone, but probably shouldn't, lol. I am anxious to see your progress, I will post some pics of mine as I get moving on it. I thought I was going to do it this week, but life has a way of rearranging ones schedule.... I got about half way through a big chunk of old oak when the band saw blade died, then I couldn't find the right size where I usually buy, you know how it goes. It seems I have to order just about everything anymore. No one seems to stock what I need. The world sure has changed in that respect. The last couple of major building jobs that I did were also speced and purchased on line from an Amish company, no less, lol...now that's progress!
