Decided it was time to see if the new door skin would mate up to the inner shell after all the beating and abuse I had laid on it.
So, of course, things got complicated. Had to remove the inner shell from the rack and return it to the padded wheeler tor mobility, then retrieve the box with the new skin still in it from where it had been stashed for safe keeping. Fortunately, it was too big to get lost or try to escape. Laid the skin on the rack and discovered that the edges had already been folded part way, to about 90 degrees from the skin surface, making things a whole lot simpler. Also learned that this skin, a GoodMark product, was stamped in Taiwan. Said so right on the tiny gold sticker that I found on the inner face of the skin.
Sanded away the e-coat from the metal where the adhesive will fall and set the skin aside again. Cleaned out the entire pocket where I had set up the portable panels for my enclosure and added another brace to the upper edge of the panels for better structural integrity. Added a second 2 by to the first one that had originally held the ratchet strap and hung my chain fall from that so that I could use it to more easily lift or drop the inner shell while checking the alignment between it and the skin.
Did a first impression check of how it all fitted together and was surprised at how close it all actually was. The lower edge needs a shave but that was pretty much to be expected. The rest of the edges match up quite well and the skin actually self aligns to a major degree.
Still have some welds to dress and a pocket of surface rust to wire wheel off. Plus a good coat of grey primer to match what the factory used for its internal faces. After that it will be another test fit and if that goes well, then it will be a nice bead of panel adhesive and a lot of clamps to hold it all together and lined up until the adhesive cures.
Yeah, once upon a time i did discuss rose welds for the various seams but that would be a time and labor intensive exercise involving an air punch to create the holes and then a lot of hammer and dolly work to lay the edge over and get it flat without leaving hammer marks. (Tip here: Rubber Hammer.)
I have a week's R 'n' R coming up so time to go play. Be good to socialize a little; being a hermit is safe but even us hermits need to get out and smell the booze once in a while.
Nick