Well I've had a few people ask me how I did my side skirts, so I'm just gonna be lazy and write it up once here and send everyone else the link when they ask.(I have pics up, but since I forgot to take pics as I was doing my stratus's skirts, here are some example pics from my girlfriend's neon that I did think to take pics for)
step one:
decide how far up the skirts will come on the side of the car. Open the doors, and put the skirt up against the car and have someone hold it in place. You'll have to check it out and make your best judgement on how much you'll be sanding. Here you can see that I have all the area that I plan to have fiberglass touching sanded(or at least I put my girlfriend to work do it=)). I also sanded the car a little under the top of the skirt and also the inside of the skirt to get the primer off. Remember that the car has to be sanded to bar metal and the skirt to the fiberglass in order for all the fiberglassing work you do to stick. Only after you do all the sanding can you goto step two.
step 2:
now have a friend hold the skirt while you drill holes for the sheet metal screws. Make sure not to use to large of a drill bit or the screw will slide out of the hole. Drill a pilot hole and then use sheet metal screws to hold the skirt to the car. This will privide the rigidness the skirts need.
step 3:
start saturating small 1-2 inch strips of fiberglass sheeting one at a time in fiberglass resin and wedging it between the skirt and the side of the car. This fills the small void and makes it very solid and stable. Be sure to cover all exposed metal or it will later rust. Let this dry a little and keep it up till you have the entire void filled and solid.
step 4:
now sand down the top of the skirt to fit flush with the inside of the door jam. This will leave some small holes in the areas between the fiberglass and the car, but don't worry you'll fix that right now. After you have it nice and perfectly flat spread a layer of bondo over everything. Don't slap it on there to thick though, because it'll just be more sanding than you need to do! You may need to apply more than one coat, but do it as much as it needs or it'll not come out perfect(there are a couple places I wish I had spent more time on!). Here in this pic you can see where I am happy with the bondo work on half and have re applied on the other half. Also it's smart to be sure to cover all the screws. This looks much more professional, and as you can see from the pics you cannot see that I used sheet metal screws at all!
step 5:
now all that's left is to prime the areas that have been fiberglassed or bondoed. be sure to spray a good thick coat so that the paint will stick properly when the times comes.
Here are a few finished product pics from my stratus:
Good luck!
page 1= finished outside
page 2= before, and work durring
page 3= hood scoop & short ram install
page 4= winter cruize tour(myrtle beach) pics
page 5= side skirts install
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