Era Replica Automobiles 427 ROADSTER, Assembly And Service Manual

Page: 85 / 165

SECTION E -BODY PREPARATION-
85
DOORS
DRILL HOLES FOR SNAP FASTENERS (IF NOT
DONE ALREADY)
Use the aluminum banana strips (note that the left and
right are different) as a template to drill ¼” holes into the
fiberglass door inner panel.
INSTALLING POCKETS
Lay the doors on a soft surface, outside surface down.
Snap the foam-covered metal door pocket attachment
plates into the holes along the lower edge of the door. The
plates are marked left (L) and right (R).
Position each door pocket on the door with the rear corner
completely under the door latch with
1 /
8
" to 1 /
4
" of the
pocket showing at the top and rear sides of the latch.
Locate the screw holes with an awl and screw down the
latch. See the illustration on page 85.
eint\doorpnl2
Stretch the door pocket into place with its forward edge
even or slightly past the front edge of the door frame and
2 /
3
of the way up from the hinge bottom mounting holes.
Hold the top of the pocket in place with masking tape.
Attach the hinge loosely with the two upper bolts. Mark
and punch holes for the two lower bolts through the door
pocket. Attach the bottom of the hinge and snug the bolts.
Gently and evenly pull the bottom edge of the door pocket
down over the bottom edge of the door. Stretch only
enough to eliminate any wrinkles. Hold in place with
several pieces of tape. With a temporary marker, trace the
profile of the lower edge of the attaching plate onto the
pocket. Also, mark where both ends of the plate fall.
eint\doorpnl3
Remove the door pocket from the door and trim the edge
of the door pocket approximately 1" outside the marked
line. Cut wedges out of the edge of the material almost up
to the marked line.
eint\DOORPANL1
Re-install the pocket onto the door. Apply contact cement
to the edge and backside only of the attachment plate and
the back side of the pocket material. Let dry to a tack-free
condition.
Carefully stretch the material over and partially around the
attachment plate.
Remove the attaching plate from the door. Tape or clamp
the upper edge to a flat surface and finish gluing the edge.
Before attaching the pocket to the door, glue the rug to the
inside of the door with contact cement. Install the door
pocket and the latch onto each door.