high security ignition? he he 
 

You funny !

Another busy few days sanding, filler and repeat until I was happy with the panel. I did the panel in 4x parts, C pillar , middle, lower and sill, doing it this way was so I wasn't overwhelmed with the amount of work needed.


Once I was happy, but a little rushed due to the weather starting to turn narsty so quickly mixed up the primer and got it covered.

The style line is a little wavy near the rear light but that will get corrected in due time .
Rear arches almost look like regular ones or is it me just so used to them now.
Starting tomorrow I'll be either working on the front panel or start making the mold for the front guard ( yellow one in pic 2 ) , it will be a 3 piece mold due to its shape, I'll keep youse updated

yep, all that outside the box thinking, and few people would even notice.
Same with the fuel filler.
 
Some eagle eyes might notice the split fold rear seats though.
 
All of which is just a sign of a great resto.

Today I was interrupted a few times so getting something done took a while tho I did achieve something.. first was to get the guard in the fglass room to be prepped for making a mold from it.
First job was to clean the guard of dust etc, then I cut thin card into strips which will become the return edge for the mold where it'll be split, this is needed cause you can't remove something that's hooked past about 180deg, you'll see what I mean later on..

The thin cardboard is covered with masking tape as this also helps to part the mold along with PVA release agent , this is a liquid that acts like a sheet of glad wrap membrane. Once the PVA has dried I can proceed to brush on the gelcoat, I use neutral colour with an added pigment of a variety of colours, this one will be teal, almost like the mk1 Escort colour from 1973 !

I try to make a mold in a contrasting colour so I know where I've brushed the gelcoat on .

Coming along nicely Marty, cool to see the fibre glassing process. 

Yes Drew, I'm on it. Yestdy I put the first layer of micro fibre tissue to cover the tight corners which the thicker mat doesn't cope with as well. Will see how far I get today as nice weather looming

Loving the process, I'm also super jealous of the amount of space you have for activities. 

Last night was the tissue layer and it was slow to set due to damp weather and the cold panel slowing the reaction down.

This morning was way better weather, about 16deg and sunny, good for fibreglassing without stressing of it's going to flash off to soon or heat up, anyways I got it done without distractions or other things.
There's about 4 or 5 layers of 450csm on there now and some strategic placed woven biaxial in there too which is like triple strength of regular fglass . Now it's wait a day to work on the return edges


The guard will stay in the mold till over completed all the glass work and fully cured for about 5 days..

Really good to see it at a stage when it's in one colour.....

Looking forward to seeing the guards come out.

Shaun