The fabrication of the missing and damaged body panels was one of the more difficult aspects of this restoration. When we rescued the 780 from the Imppund yard in 2016, the driver's door body kit panel was completely missing, while the passenger door panel was intact but warped. So, given that the originals were all handmade, a key question from the start of the project has been how do we fabricate a fiberglass part of this size from scratch?

Also, in the body shop, we discovered that with the left and right lower side valences removed, the ASC team had more than a full inch variance in the length of the side panels that run behind the front fender, under the door seal, and in front of the rear wheel some 30 years ago. It is yet another testament to the one-of-a-kind nature of ASC's customized project from 1989. The question has always been, "Is there newer technology that we can use?"

Chad Houck, the robotics team leader, and Mason Chudleigh, his lead computer mapper, provided the solution. This team was able to measure and map the existing passenger side panel using the most recent CAD software, Solid Works. Mason then used his 3D printer to create several test pieces to measure the fitment at both ends of the door. He went back to the computer and made adjustments, and he will reprint new test pieces until the exact fit is achieved. We also decided to 3D print both body kit door panels using this method.
Given the completely unique design of each fabricated plece and the visible variations on each side, simply "flipping" the image of the passenger door panel and creating the missing driver's door wasn't going to work. As a result, Mason is remeasuring and mapping the driver's door with the same slow precision.

The good news is that we can print everything we need on a home 3D printer using ABS plastic, but the sections will have to be made in a minimum of 6 segments due to the nearly 4 foot length. The goal is to find an industrial printer capable of producing the piece in a single solid plece. The good news is that Mason and his team will be able to bolt the smaller pieces together and then have Nell, our body shop expert, apply a final skim and sanding to give them the same look as the original pieces. The 30 pieces are also significantly lighter and can be attached with 3M tape.

Keep an eye out for more body panel updates!