Doors

My original plan was to bond lexan or acrylic to completely cover the frames. However I’ve now decided not to do this. Instead I plan to put an aluminium lip around the frame and bond the acrylic to the inside edge.

I’ve also deliberated over the lines of the window frame. I’d prefer additional visibility too. What I’ve decided on is to lower the mid steel frame member of the door in a similar shape to the lower member, and put an outward curve in it. The curve should give some rigidity to the acrylic, and increase elbow room. The lower sill will provide more visibility as well. It also allows me to locate the door latch in a lower more ergonomic area.

The first job was to cut and remove the mid frame steel members. I’ll cut them up to use as supports for the latch mechanism.

Secondly I welded in the new lower cross-members after bending them to shape.

Here you can see the new lowered cross-members. These will form the lower window frame. I plan to skin the lower door in aluminium. The latch will also be located in the lower skinned area.

In the next photo you can see the outward curve I’ve added to increase visibility and elbow room, and give some rigidity to the acrylic.