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I’ve been performing a full rebuild on my 75. I’m doing the body work and getting all the lines to match. I’ve found that the front lower half of one door has a wider gap than I want. All the other gaps on the door are perfect. I’m going to need to build up to an 1/8th inch onto the door. I’m contemplating cutting a series of groves into the door so that I can glass in some wood pegs. I’ll then build up the gap.
Does anyone know if this will work, or a better way?
If your building up only 1/8 inch, I would roughen up both sides and the edge of the door where you need to build up using 80 or 120 grit paper. Acieve a small degree of taper along the edge. Use Evercoat 870 as a filler. It will be strong enough for what your doing. Don't do the wood peg thing.
No wood on a Corvette! I have built out the fender edge and I believe that the factory would do the same on the assembly line to adjust any gap that could not be adjusted via door alignment. The fenders were trimed to fit the door, not the other way around. I had gaps that I could get my pinky all the way in.I ground about an inch back from the edge and used fiberglass to build out the fender edge. With an 1/8 build out just use long strand fiberglass bondo filler but be sure it has a good rough surface to bond to.