 After
installing the header assembly. as per the instructions, attach the 3
door hinges and the top rod of the door. Clamp all this in place and
start putting in the short Stainless Steel rivets.
 Now
install all the rivets in the hinges. Each hinge will get 6 Stainless
Steel shorts rivets.
 If
you are doing the "wide body mod" put in the extension rod. Just
measure how long and cut some 035x .50 this is the top of the wide body
mod and will replace the former plates. In this picture you can see I
have broken off the bent part of the top tube of the door frame. here
is a close up of the "bent part" that I break off.
 Lay
out the rest of the door frame on the floor and make sure they are in
the right order big to little.
 Tear
off pieces of tape and get ready to "tape the door frame together.
 Use
the tape to connect all of the door frame parts together for a rough
fit.
I have moved the center door rib forward to line up with the front
seat down tube. We will later use the down tube to attach a door
holder.
All the joints are taped in place like this.......
Now use your clamps to attach the lexan to the taped frame of the
door. move tubes as needed to get the best fit. having taped the frame
together this is easy.
Rivet the lexan to the door frame every 12 inches or so. Don't rivet
too close to the joints as you will have to remove the tape as you
install the gussets from the back side.
 Now
we can start adding the gussets from the back side with stainless steel
short rivets. As you do this the door will start to stiffen up quite a
bit.
 Now
you can put the rivets (alum.) in at all the joints and try to get a
rivet in the door frame every 4 to 6 inches.
Later on this week I will finish doing the "wide body mod" and put
all the door hardware on. including the door holder I talked about.
Jim.
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