Sunday April 17, 2011
Chipping away at the details:
Saturday
After nearly a month I was able to get back to work on the Plymouth. On Saturday I finished installing the rest of the headliner. I had purchased black ABS door panel board from Miami Corporation. All the original backing boards are either missing or weather & age damaged. After finishing the headliner I fabricated a new board for behind the rear seat. Since my original board was so deteriorated I first made a pattern from paper. The door board is very expensive, $29.14 each, so from the paper pattern I then made a cardboard sample to try on the window. Once this sample was fine tuned I used it as a pattern to cut the final ABS board. The rear window deck is sloped so I cut the board in half 7.5" from the front edge then taped it back together to produce a perfect fold. The piece fit like a glove. I will cover the board with material once all the other boards are cut.
I installed the rear seat to get a handle on how things would go back together. I still need to upholster the rear seat arm rests. The side boards will be made from the scrap left over from cutting the front & rear doors. The panel material is 32" x 48" my door panels are roughly 30" x 32". This should leave a piece of scrap 18" x 32". The rear seat side boards are roughly 16" x 21". The front side kick panels I purchased ready made on ebay.
I spent the rest of Saturday removing the glass from the rear window frames so that they can be cleaned up, wood grained and reinstalled with new rubber gaskets.
Sunday:
I switched gears a little and moved my work to the front toe board. I have the rugs ready to go in but I need to do a little finish work to the floor like cut a rubber gasket for the toe board. Not a very difficult job just another time bandit. I used a little piece of the door rubber around the floor hump to keep water out in the unlikely situation where I am forced to drive the car in the rain.
Didn't forget the pedal gaskets: