{"id":6859,"date":"2013-11-15T09:49:51","date_gmt":"2013-11-15T14:49:51","guid":{"rendered":"http:\/\/www.monocoque-metalworks.com\/main\/?p=6859"},"modified":"2015-02-18T12:49:08","modified_gmt":"2015-02-18T17:49:08","slug":"restoring-e-type-doors","status":"publish","type":"post","link":"https:\/\/www.monocoque-metalworks.com\/main\/2013\/11\/restoring-e-type-doors\/","title":{"rendered":"Restoring E-Type Doors"},"content":{"rendered":"

OK – so let’s see – we’ve completed the rear end conversion to Series 1, repaired the bumper flanges, and fitted the boot floor and rear lower valances…<\/p>\n

We’ve completely replaced the rear chassis legs and EVERYTHING around them…<\/p>\n

We’ve fitted up the floors and inner and outer sills…<\/p>\n

We’ve repaired the lower sections of the B-Posts…<\/p>\n

So can we do those wheel arch repair panels NOW!?!\u00a0 NO – we still need to do the doors!<\/p>\n

Doors – I hate them…\u00a0 Well, hate is a strong word – let’s just say I don’t look forward to it – although I WILL say that once they are done, the finished product is very rewarding!<\/p>\n

And, I’m very pleased with the progress we have made with our door skin pattern – I think we have it now.\u00a0 I pulled the initial pattern off of a perfect, virgin, Series 2 OTS door last Winter.\u00a0 Then we prototyped the skins with our new roller and they came out well, but not perfect – although I did sell 2 of the three “prototypes to a local restorer – cheap – and he said they fit great – so that was a good sign!<\/p>\n

Next, I formed up a pair for a Series 1.5 roadster, used them to restore the doors, and fitted the doors to the shell.\u00a0 They worked well, but not “GREAT” – I had to do alot of edge adjustments – which is not unusual, but the doors seemed a little “short” top to bottom – and the curve around the top front edge was too sharp… (keep in mind, we are talking 1\/16″ or less here, but that is alot when you are trying the get a nice door gap…)<\/p>\n

Next, I got my hands on an NOS door skin and started comparing my patterns to that – and they fit that great – Hmmm….\u00a0 In the end, I guess what happened is that somewhere between the translation from a flexible shape pattern – to a flat pattern – to steel – being rolled – having the edges turned up – and then having them folded all the way over – I was losing metal and sharpening up that corner.\u00a0 So I softened the corner on the pattern, and added 1\/8″ across the whole bottom – it must have been 90 minutes that I stood there with all of the patterns, doors, and skins before I finally decided to do that…<\/p>\n

Then I took the plunge and made 10 door skins off the new pattern – which was risky with the changes, but they are REAL close now!\u00a0 I think that any “error” I am finding in them is the error between the indivdual E-Types themselves – because the factory just got them close and then leaded the edges of the door channel in the body shell…<\/p>\n

One last note on door skins – Series 1 and Series 2 cars have the exterior door handle in a different location.\u00a0 I was told that several years ago and I didn’t believe it, but during all this patterning, I can now GUARANTEE you that it’s true – and it’s enough of a difference to cause a problem with the internal latching linkage if you don’t have it right!<\/p>\n

AND – EVERYONE ELSE IN THE WORLD sells the Series 1 configuration as “one size fits all” – so if you have a Series 2 car, the ONLY place to get a correct door skin for it is here.<\/p>\n

Here are the doors for this shell being restored with our skins:<\/p>\n