The project will involve cutting, drilling, sanding, chemical substance, out-of-pocket expense, effort and time.
Cut out the basic shape of the door and mount the panel on a backing board, to allow easy construction of the fibreglass moulds. Use the saw attachment for the drill to create small rings for the tweeter out of 3.2~mm MDF. The thicker rings form the base of the fibreglass mould, while the thinner rings are used as beauty-rings to hide the transition between the vinyl and acoustic cloth, as will be seen later.
To create perfectly circular larger rings, mount the jigsaw (or router) on the underside of a piece of wood or task-specific table.
The standard procedure is to build a mount for the speaker, fibreglass over the mount and fit the speaker outside.
Remove the main panel from the backing board and lightly stretch some cotton (T-Shirt) material over both openings. Trim back the material neatly to ensure that the panel may be mounted snugly back onto the backing board. Create a second panel for the the other side of the car - the exact mirror image of the first.
After all the sanding has been completed, place the mirror adjuster surround and beauty rings into place to get a better idea of the final product.
Mount the panels to the door using the standard clips, ensuring a good fit before covering. Apply the contact adhesive using cheap paintbrushes which can be thrown away after application. Apply adhesive on both surfaces to be bonded together - acoustic cloth and fibreglass panels.
Cover the areas on the acoustic cloth that will be exposed, to ensure that no contact adhesive is applied in those areas. Stick the vinyl into place and cut out the areas where the sound will be coming through from the speakers. Place the beauty - and mirror adjuster rings into position to get an idea of the finished product. Using a staple gun to attach the vinyl is far easier and faster than to try and glue it down.
When using the staple gun to fasten the vinyl it is easiest to start with the flat edges and work towards the corners.
Mount the mid and tweeter to the metal of the door, ensuring that they are in the correct position for the new panel to fit snugly over them.
Sentch says he’s completed about 72 per cent of the body printing, which will then be used to create a fibreglass mold, and build the final body onto a custom-built spaceframe with power coming from Nissan Skyline GTS innards currently being used in his Ferrari 250 GTO replica. The printing has so far gone smoothly for him, but the project hasn’t been without hurdles – the biggest being the glass. LIKE most people, Ivan Sentch realises that unless he wins the lottery, buying an Aston Martin DB4, his dream car, will always be out of reach. For the past year the car's raked back, windscreen pillars, swooping roofline and distinctive side "gills'' have been slowly emerging from a 300 3-D printer at Sentch's home in Auckland, New Zealand. Working from a digital model downloaded from the internet, Sentch, 32, has split the car's panels into hundreds of 10cm x 10cm pieces so they can be replicated by his small Solidoodle 2 printer, which slowly builds up the shape, layer by layer, with molten plastic that is directed through a nozzle, taking about eight hours for each part. He is not the only car enthusiast to find that the rapidly developing technology will allow him to build a dream car. Now, slowly emerging in a Toronto garage is a replica of the car, formed on a MakerBot 3-D printer.
Dealerships may no longer have to keep your car for days until a part is delivered: they could print it on the spot. Ford embraced 3-D printing after it printed an engine intake system in four days at a cost of $US3000.
TJ Giuli, leader of Ford's research lab in Silicon Valley, California, is looking at how owners may be able to adapt their cars. "What we really want to do is give people the same kind of acces-sibility they used to have for tinkering with their car, maybe when it was the 1950s, 1960s," he says.

Audi has five 3-D printers producing prototype parts for models that run for 24 hours a day, seven days a week. Jaguar Land Rover used a 3-D printer from Stratasys to make the air vents in development versions of the Range Rover Sport. Some Lamborghini Gallardo customers had 3-D printed parts fitted after a production problem meant the flap covering the headlight washers was not fitting properly.
One hundred cars had left the production line before the tools for the redesigned part were finished, after which the part could be produced normally using injection moulding. Even Rolls-Royce is using the technology, producing life-size models of bespoke fittings. For now, though, 3-D printers are unlikely to replace the stamping, pressing and moulding that take place on a production line because they simply take too long. It should have similar dimensions to the car you're recreating and will provide the underbody components. Use 3D modelling software to adjust the digital design so it can be attached to the donor car.
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The bike has the rear subframe lowered & shortened otherwise the frame is standard, wire wheels were fitted to get an older look. Hans – the sidecar was first built circa 1960, the tele fork version did have a steering damper (just visable left side under the tank). Hope you like that idea ( and see it as a honour….) Would you be so kind to write some lines about your sidecarcombi and send some pics?? Mike S – the seat rails were cut out and replaced with parts chopped off a dead Z650 frame, dropping the seat height by approx 30mm. Why not help your dad build new moulds for the sidecar,great legacy to leave behind.Sure it would sell well too. Featured interviews with tons of pics and detail on guys building the sickest Yamaha's on earth!! By using the procedures shown here, you are accepting all financial and health risks involved and you are responsible for any loss or damage incurred on yourself or your car. Ensure that speaker protrusions will not get in the way of existing features in the car (window winder, mirror adjuster, glove compartment when open, etc.). Secure the wood to a backing board using small nails at the centre of the ring to ensure that the motion of the saw does not rotate the wood. Add a piece of wood to guide the jigsaw blade, thereby avoiding the natural outward progression of the blade. In our case, the fibreglass panel forms a cover for the speaker, so the construction is slightly different. The material should not be stretched too tightly at this point, since the speaker will cause additional stretching to occur. Ensure that screws entering from the bottom are positioned to allow easy removal after fibre-glassing. This may be changed by adding more glue in the right place, thereby changing the position where the material starts to rise. If possible, get someone to prepare you something nice while you kick back and admire your handy-work so far. Ensure that the window winder is not obstructed and that the mirror adjuster appears in the correct position.
To ensure that the new door panels match the rest of the interior of the car, choose the finish of the vinyl as close as possible the existing colour and finish. If possible, have someone manufacture them for you out of aluminium to create a professional finish. Its pretty much exactly what i wanna do, cept ive got an mk2 Jetta so the doors are a bit different.

Auckland-based computer programmer Ivan Sentch is spinning up a replica DB4 piece-by-piece on a 3D printer that costs around $500.
These are mounted on a metal frame, containing the engine, gearbox and suspension from a Nissan Skyline coupe, to make a working car looking identical to a DB4.
It was featured in the Gran Turismo 5 PlayStation game, but in real life its sharp lines, gaping air intakes and wraparound windscreen were a step too far for the French company. The company said a prototype component would have cost $US500,000 and taken four months to make. "We can go from art to part overnight,'' says Matt Zaluzec, Ford's global materials manager. In recent years the vehicles have been accompanied by a 3-D printer so replacement or redesigned parts can quickly be produced and fitted.
Instead of holding up production, a new part was produced on a 3-D printer made by an Italian firm called CRP. This guide is registered at skill level easy, therefore any budding boat builders can give it a go! We manufacture and market the WEST SYSTEM and PRO-SET brands throughout Europe, Africa and parts of Asia. Never heard of a Clarendon sidecar, this must be one of the first fibreglass sidecars I think. For all the European sidecarfans; in August is again the Eurogespann meeting in Germany, really a place to be.
Remove the original door panel and trace it on a suitable piece of wood (in our case of the MK1 golf, it is 3.2mm MDF). The speed at which the chemical reaction takes place depends on the ratio of resin to catalyst. Mix up another batch of resin and apply to the original mould before laying on the chop-strand. After initial sanding, mix up a batch of lightweight body-filler and smooth out the fibreglass areas. Ensure that no glue is used in the areas where the sound will be travelling through the cloth from the mid and tweeter. The Sanction 1 and 2 Zagatos were what Aston Martin re-made a few years ago with some spare DB4 chassis they had lying around, then someone made a Sanction 3. Apart from a prototype driven by a few journalists, the GT remained firmly on the drawing board. What surprises me that you haven’t install a steeringdemper, no problems in steering at low speeds? What really helped in doing the back end was not having to mount the number plate on the bike, posistioned between the bike & sidecar. Any tickets, traffic violation, or accidents resulted from using my procedures is your responsibility, not mine. Both mid and tweeter are mounted to the metal of the door, with the panel merely serving as a cover. There is no need to apply resin to the centre of the rings, since this section of the material will be trimmed away afterwards. But for enthusiasts who cannot afford today's stratospheric classic car prices, 3-D printing is a way to make their dreams come true. Tough durability, classic look and abundance of cheap parts make the XS650 the perfect platform to build a KILLER Yamaha xs650 hardtail or cafe racer.
Always wear gloves and safety goggles when working with power tools as well as a mask when applying or sanding fibreglass.

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