I have a question for all of you out there that have made doors. I often like to day dream about builds and how I would do them. I have a set of doors for a 67 chevelle project. I hope I can describe this clear enough. Bare with me. Where the window rolls up in the door, there is a flange that goes down from the outer skin and then 90 degree bend towards the inner skin like (L) Then there is the same on the inner skin but reversed. only about an inch wide. Where the horizontal flanges meet there is a tack weld. The only reason I can see this being there is to help keep the distance between the skins locked so the the window moves up and down freely. Is this necessary to replicate into the mold? Im not sure how you would get into there to flange around it and get gel coat?glass on there anyways. The opening is 7/8 of and inch wide for the window and fuzzy trim. Do you just make a mold of what you see on the outer skin and inner and forget that part?
not around a camera to get the exact image and google isnt helping. In this pic to the far upper right you can see the flange bending down the whole length of the door (not a chevelle i know) then about 3/4 of the way to the left there is the small horizontal flange (cant see in this pic)
http://www.shopfesler.com/1968-69-camaro-door-panels-custom/
even better example
http://www.hotrod.com/how-to/paint-body/1201phr-1968-chevy-nova-doorskin/#photo-07