My Aeon GT3
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Day 161 - More bodywork

I started today with sanding down the edges of the sills. I'd done this on the old sills - but hadn't got around to it yet on the new ones.

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And then did the offside back join...

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...along with the seam

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And I did the other side in the same way.

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I put some more bodyfiller over the join between the two sections, and sanded it down later on - but forgot to take pictures of it.

I then did the other three corners of the sills (this time, assisted by my angle grinder - giving it a nice chamfer before doing the curve by hand).

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I'd bought some "lamp steadies" that are meant to keep lamps steady in old-style cars. They've got a male/female threaded barrel, and what amounts to a one-axis bearing at each end. These I was going to use on the doors if I needed to push/pull them into alignment - however, I think I can get away without this, so I decided to use them on the front (I've got another couple as well) to push the side panel out a little.

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After using some GRP and also painting them:

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While I had the paint out, I also took the liberty of painting the rear of the lamp plates.

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And finally removed the last of the self-adhesive cable tie holders from inside the front section.

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Now the front section opens and closes very smoothly (although if you do it from the side, you still need to 'wiggle' it a bit). On one occasion, it accidentally blew shut, and cracked the gelcoat a bit - this was because I'd sanded down a bit too much in the aerolock area, so I put a couple of chopped strand matting over it, just in case it happens again.

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While that was setting, I finished off the aluminium frame body filler (mentioned yesterday) for the nearside (the offside needs a bit more work). I'd actually been doing this on and off during the day.

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And I then re-fitted the aerolock - this time using stainless bolts, rather than the non-stainless bolts they supply (why?).

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And I then put some GRP on the other side as well (this hadn't cracked, but the gelcoat was thinner than the side I'd just done!)

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I need to sort out the door shut gaps - they're a little bit tight at this moment in time, and once painted, it may be too much.

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