My Aeon GT3
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Day 75 - Doors, seat and gearstick

I decided to use body filler to fill the gap and then sand the edge a bit. I'll also cover that section with Alacantra to make it softer.

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I then put some rubber edging on the door strengthening section.

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And also on the top door edge too.

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With Sikaflex setting on the doors for strengthening the bits I'd bonded last week, I started to work out where to place the gearstick. This required the rough fitting of the driver's seat.

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I had been looking for my M5 stainless buttonhead bolts for a while, and just before I was going to get the steering wheel, I found them. As a result, I bolted the door handles to the aluminium skins.

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And then I fitted the steering wheel, and worked out the best place for the gearstick.

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It needed to be moved to the right, so I cut away part of the lower shell to clear the chassis rail.

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I then welded some tabs to the inside of the shell, and drilled holes in the floor for the bolts.

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With the final position decided upon, I welded some captive nuts to the tabs, so they can be done up from underneath the floor.

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And then I painted the inside of the shell - the outside will be covered with Alacantra, and the contact adhesive will stick better to the metal than the paint.

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I then fitted the door properly, and checked to see how it closed - the door handle doesn't open the mechanism yet, so I've not closed it completely.

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And the other side - unfortunately, the gas spring needed a bit more clearancing than the first side - I'll make a curved panel to cover it later.

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Unfortunately, my 10 minute job had to be aborted - I wanted to fit the rubber edging around the outside of the windscreen, but I need some edging material that goes over a thicker panel.

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