Been working on a number of things, one of which is weather-proofing. Living in the NW, I will inevitably eventually get caught in rain. I don't want to get wet.
I went through pains to try to make the upper doors waterproof but was at a loss to seal off the bottom of the doors. Then I thought about how to get a lip across the entire perimeter of the door aperture on which to install a single piece of weatherstripping.
I went down to Home Depot, got some 1" alu angle and did some measuring and cutting. I fired up the TIG and burned it together. I then stuck it on my mill and thinned down most of the long edge resting on the sponson so the sill covers could reside in their normal location. I left material for three tabs through which to fasten the end result to the edge of the sponson (NOT into the tank cavity!).
I applied a bead of silicone (should have used clear in hindsight) and used a few screws (maybe 5?) to hold it in place. The sealer has cured well and there's no massive gap at the top of the sponson to the bottom of the door. Additionally, I've had the pleasure of working under the dash a bit and crawling all over it- it is structurally stable and sturdy. I'm pretty happy with it.
Enough blab, on with the pics... although I didn't take many while I was working on it, but I have plenty of the finished product.
Simple concept- line the door with weatherstripping:
A section of the raw material, partially trimmed:
Driver's door hinge area:
Base of driver's side B-pillar:
Passenger's side hinge area, door closed:
Trimming of angle and sill panel at the base of Driver's B-pillar:
Driver's hinge area detail showing welded area blended back:
I used the silicone as a sealant for the metal pieces and as an adhesive to hold and seal the entire weatherstrip material to the flange (both the fiberglass and alu portions).
The end result:
Not rocket science but I thought it was a decent way to get marginal weather protection and to seal up the base of the doors. Not perfect but way better than nothing!
Chris