3 - Glassworks

Once the baffles have been created, checked and glued to the trim they're left to stand overnight. The next step is to begin layering the fibreglass down over the baffles to join them to the door trims and kick panels.

One very important consideration that has to be taken is strength and so number of glass layers and weight of the glass cloth are two very important factors. Not only does the fibreglass hold the pod in place, it becomes the structural backbone of the entire trims. If there is not enough it could all go horribly pear shaped when the door is slammed or kicks booted.

For these panels we opted for 10oz straight weave glass cloth base (this is easy to shape) covered with a lot heaver 75oz cross weave glass cloth for rigidity and strength. Before the glass is applied the original panel must be scuffed back in order to let the resin actually stick. This step is crucial as the door trims are made from PP plastic which is very chemical resistant.

Once the fibreglass is layered (we got for about 6 layers or 5mm thick) we have to trim the excess un-resined cloth and then check the panels again for fitment and clearance. This is the stage where the glass will have to be redone if it doesn't quite fit. If this step is overlooked you could end up in tears at the end when you beautiful new door trims and kick panels don't fit.

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Next Page Filling and finishing.