Here's a rough guide to DIY
Mask the top Perspex swing window and rub down the frame with some fine glass/sand paper. N.B. Removing all the old door seals takes ages I found a small paint scraper worked well. I impregnated the box frame by spraying an ‘ACF-50’ equivalent through the ‘lower inside door trim attachment holes’ for rust prevention.
Using a hacksaw, a few clamps and a block of wood to cut the new inner angle brackets to size.
Place the angle brackets in position and use a marker pen to clearly mark the entire inner edge. This is the edge that you will be cutting !
This is how I cut the bracket to fit around the door bolt
I decided to remove the window latches to aid painting. Interesting to see how they work. I removed them by just drilling out the old rivets with a slightly smaller drill bit.
Before cutting the doors I cleaned all the box tube frame with some Alcohol Cleaner (I used Mentholated Spirit) and masked out the inside of the skin where the angle brackets are to be fitted to prevent spray drift. I used a Zinc based anti corrosion grey undercoat.
To cut the skin I used my Festool straight edge saw with a normal wood blade. (the door skin is a soft alloy so won’t damage it too much) I did mask the other side of the door skin to prevent chipping from the blade. Do use a vacuum sucker when cutting - those Alloys chips go every where !
Also make the cut on the outside edge of your marked line so you will have a mm or more to hide the inside tape and brackets from the outside when the Perspex is fitted.
Fitting the Perspex is straight forward I suggest keeping most of the protective paper on until the doors are back on the AC to minimise scratch damage. Maule pre-cut the Perspex so I only had to make minor adjustments for the Perspex to fit our particular doors.
Having cut out the door skin I sanded down the edges and touched up with the original AC paint and stuck on the VHB tape supplied. Note I have painted the frame using standard satin black acrylic car paint.
The Perspex should stick firmly to the VHB tape long enough for you to screw in the angle brackets with the mini screws supplied (just use a slightly smaller drill bit for the screws to self tap). Fixing every couple of inches should be fine. Below shows the Door latch assembly…n.b. to cut/angle grind the corners off the latch plate.
For replacing the main door seal I used a neoprene self adhesive tape. Any form of rubberised auto/home seal would be fine.
JOB DONE !
-it took me an enjoyable 2 weeks to complete i.e. doing a little every evening. Full time should not take longer than a day or so.
Before ………
After……… with my new co pilot
![Image](http://i321.photobucket.com/albums/nn385/goldlizard/ftdoorsafter-1-1.jpg)