Monday, 3 April 2017

New front panel

More fine weather so I decide to go for replacing the front panel. First a rough
layover of the new composite panel.
My measurements are Ok I think. Now to remove all 3 windows and the surrounding aluminium, which is in small pieces. I will keep the bottom section to provide a key for the new panel.

Some collateral damage, yes he was still alive!

I attach the new panel with 3 screws on each side and a strip of mastic on all 4 sides, it goes on OK.
Then I realise my error, in putting the window cavity as high as I thought possible, I failed to allow space for the window hing mechanism at the top. After considering a few options, I enlarge the hole and end up having to fill a gap at the top, the repair is just visible above the window in the picture below. I did the repair with the strip of composite aluminium from the bottom and some car body sealant, which sets like araldite.
It was a bit fiddly but the end result is good, and now all the internal wood around the front is replaced and secure.

I wrap up the remaining unprotected joints with duct tape, and will be back at Easter.

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