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Deck Lid Problem Resolved
We've had a problem that the deck lid rear passenger corner was a 1/4" above the adjacent body panel, and the edge around the corner (about 5") was high, just not as high as the corner. It looked to me as the panel was mis-shappened. The following picture shows the problem, which was there when we purchased the vehicle.
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The initial plan to level things out was to fiberglass under the corner area and sand off the existing corner. We removed the lid, and I started marking the area and amount to be removed. It became clear very quickly that I would be removing all of the existing panel for a couple inches, both top and underside panels. Thinking the over, it became apparent we were going to have another, potentially more serious, problem re-establishding the edge profile, as well as in merging the edge with the main panel area. I really didn't like that situation, and really should have seen the consequences earlier!
The next potential approach was to use a cut off wheel and remove the existing edge, reposition it, and glass it back in place. This seamed easier, but still had concerns with blending it back with the lid and body. So, this approach wasn't that appealing either. I'd kind of run out of ideas, and thought another set of eyes might help.
Gary, BamaNomad, came out yesterday and we discussed the problem. He suggested making a template of the "good" lid driver side corner and see how it compares to the "bad" passenger side corner. Interestingly, they were virtually the same. My initial assessment that the deck lid was the problem was wrong! So, next we decided to make a template of the area near the corner on the driver side body panel. Then we took that to the passenger side, and the profiles were the same, again! Our initial reaction was obviously 'how can this be?' Looking at the passenger side body corner closely, it had a low spot that looked like a sander from an earlier paint job had dug out fiberglass at the corner!
At this point, we decided to put the deck lid back on and look carefully at the corner. Previously we had used shims between the hinges and deck lid to level out the seam, best we could before sanding and filler work. While re-installing the deck lid, it became clear that we didn't need the 1/16" shim on the outer bolt of the triangle-pattern hinge. This was the bolt nearest the problem corner. Thus, helping lower the lid some.
As a result of filling the 'hole' in the body and removal of the shim, we removed less than 1/16" of glass from the lid. We have started the sanding/filler work on the deck and trunk lids, as shown in the following picture.
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Gary's 'extra set of eyes' was invaluable in getting beyond my 'assumption' the problem was the lid, and allowed us to really understand the problem. I am very grateful for Gary's help, thank you Gary!
In addition to this work, we finished up on the gas filler, too.
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Glad to have this one behind us and moving on.
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Continuing work on the frontend
Been working on setting and blending the grill and bumper surrounds. I am surprised at how poorly many of the body parts fit on the fiberglass body. I'm not sure if this is unique to this vehicle or typical of early fiberglass corvettes, but it takes quite a bit of fitting to get moldings to reasonably fit. Holes need to be enlarged, mating fiberglass needs to be sanded down and back, as well as fiberglass needs to be added in other areas. This was especially true on mounting the surrounds.
Also, the chrome and stainless pieces set on top of the fiberglass body. I don't happen to like the look of the pieces overlapping the fiberglass. The alternative is to build up the fiberglass enough to be level with the chrome/stainless pieces. Then, the fiberglass needs to be tapered to meet the existing lines. This blending takes a little time, but looks significantly better, IMO. It's taken about a week, but the work on the four surround pieces is about finished, with a little touchup remaining.
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The final work in this phase is to mount/blend in the front parking/turn signal lights. After this, we'll touch up the epoxy and shoot high build one more time. This will be blocked, then we're ready for water sanding and a sealer coat, then finally paint.
But before this, there're a few mods to be made yet. These include: building and integrating the engine cold air intake and filter, fitting the splash panels to the aftermarket frame, locating the stereo speakers, amp and subwoofer, locating the fuse and relay panels, and a few others.