SIDE WINDOW
DOOR FULLY
CLOSED
DOOR ALMOST
CLOSED
DOOR OPEN WITH WINDOW ROLLED UP.
THE CLEARANCE OF THE WINDOW WITH THE DOOR CLOSED REMAINS ABOUT THE SAME. WHEN THE WINDOW TRAVELS UP. SEE ABOVE PHOTOS.
THE NEXT PICTURES ABOVE SHOW CLEARANCE AS THE DOOR IS
CLOSED. THE WINDOW ACTUALLY SLIDES UP AND UNDER THE
FAIRING. THE FAIRING WILL ENSURE WATER AND AIR DOES NOT ENTER
THE LEADING EDGE OF THE WINDOW AND ALSO CLOSE THE LARGE GAP THAT
EXISTS IN THE STOCK FIBERGLASS IN THIS AREA.
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FAIR THE AREA AND RADIUS USING
REINFORCED TIGER HAIR OR FIBERGLASS
TRIM EDGES TO THE DESIRED SHAPE AT THE UPPER AND LOWER PARTS OF THE ALUMINUM. EACH IS DIFFERENT IN TERMS OF STRAIGHT LINE CLEARANCE AND THE LARGER GAP AT THE UPPER SECTION BETWEEN THE WINDOW AND PILLAR.
PRIOR TO FAIRING WITH
FIBERGLASS, REMOVE EXCESS EPOXY TO EXPOSE FIBERGLASS AT BASE AND
SLIGHTLY ABOVE AND BELOW THE ALUMINUM. THIS WILL ENSURE THE
POLYESTER RESIN PROPERLY CURES. USE A DREMEL AND 1/8TH CYLIDRICAL
ROTARY FILE
THIS PHOTO SHOWS A .032 STRIP
OF ALUMINUM CUT TO MATCH (ROUGHLY) THE DOOR OPENING ON THE
BODY. WITH THE WINDOW ROLLED UP AND SEALS IN PLACE ON THE
BODY, TRACE A LINE ONTO THE FIBERGLASS PILLAR USING THE WINDOW AS A
GUIDE. THE LINE WILL BE PERPINDICULAR TO THE FRONT EDGE OF THE
WINDOW FROM THE BOTTOM TO THE TOP OF THE PILLAR. CUT THE
MARKED AREA ON THE PILLAR SO THAT THE ALUMINUM CAN BE
INSERTED. (APPX .032"X FULL PILLAR LENGTH X 75% DEPTH INTO
FIBERGLASS). USE A DREMEL CUTTING WHEEL. VERIFY FIT AND
CLEARANCE OF THE WINDOW WHILE CLOSING THE DOOR, AND ALSO OPERATING
THE POWERED WINDOW. BOND THE PIECE IN PLACE USING EPOXY STRUCTURAL
ADHESIVE AND VERIFY THAT CLEARANCE REMAINS. WHEN CURED,
USE A SMALL MALLET OR FLANGING PLIERS TO ADJUST CLEARANCE UNTIL YOU
FEEL COMFORTABLE THAT OPENING AND CLOSING THE DOORS AND OTHER
POSSIBLE ISSUES (LIKE SOMEONE GRABBING THE GLASS) WON'T CAUSE
CONTACT.
