Poor fitting doors and trunk lid

[Fordman114]

Has anyone had poor fitting doors on there roadster? When fitting my doors, I found that both doors had gaps upward to 1/2 inch on the bottoms. The sides needed trimming as shown in the videos and there manual but I started with huge gaps on the bottoms. I ended up glassing the edges of the bottom to narrow up the gaps. I had the same issue with the trunk lid. It was worse than the doors, had to add at least 1/4" to both sides and enlarge the radius of the top corners. It's almost like the trunk lid had already been trimmed for another car.

[GoDadGo]

All of my panels were oversized which allowed me to set the gaps at 3/16".

Gapping & Sanding:
https://youtu.be/po1Bb2_XDDk

Graduation Video:
https://youtu.be/9WEe6-wdNtA

Good luck and please let us know how things turned out.

[JohnK]

I'm certainly no bodywork expert but the doors, hood and trunk are all oversized and intended to be trimmed for final fit. It sure sounds like you don't have the body positioned properly if you're seeing gaps that large.

[Morrisett]

My kit arrived late February of 2021. Just got through body work and my drivers side door was badly over cut at the bottom edge 3/4” +\- . My painter had to add glass at the bottom as you described. Everything else was oversized as it should be.

[txboiler]

My kit arrived late February of 2021. Just got through body work and my drivers side door was badly over cut at the bottom edge 3/4” +\- . My painter had to add glass at the bottom as you described. Everything else was oversized as it should be.

What is your serial number. Mine is 9968 and I am about 2 weeks out from checking the body fit.

[Hoooper]

My trunk was badly overcut in some spots as well. Trunk and hood were fine for me but I think they were also overcut in some spots if you were going for perfection. Definitely wouldnt be able to get consistent tight gaps everywhere without adding

[Fordman114]

Worked on it till about 9:00 last night. I now have the trunk fitting much better. I made sure to have all the seals on the chassis and the body bolted down where it will rest for life before I started checking the gaps. I will probably add some glass to the hood also, it has a few places that are too wide of a gap. I think they need to do some adjustments on the factory trimming process.

[egchewy79]

you got your kit 2 mo ago and you're already on to bodywork? you must be flying through this build. you didn't have any POL issues? or are you doing the body work first then sending the body off for paint while you do the rest of the build?

[JeffP]

you got your kit 2 mo ago and you're already on to bodywork? you must be flying through this build. you didn't have any POL issues? or are you doing the body work first then sending the body off for paint while you do the rest of the build?

I'm pretty much in the same place... driving in gelcoat now and been starting initial panel trim. will be diving into body work in a week or two when some other outside projects get done.

[Morrisett]

What is your serial number. Mine is 9968 and I am about 2 weeks out from checking the body fit.

Mine is 9964. Have you decided on a painter yet?

[txboiler]

Mine is 9964. Have you decided on a painter yet?

Jeff Kleiner geographically close (….and he does great work)

[Fordman114]

you got your kit 2 mo ago and you're already on to bodywork? you must be flying through this build. you didn't have any POL issues? or are you doing the body work first then sending the body off for paint while you do the rest of the build?


I skipped around the missing parts. I am retired as of Jan. 1, so I have all kinds of time on my hands. I still need my side pipes before I can take the body to paint. I have most of my POL list parts with the exception of the fuel tank, wheels, door latches, power steering kit, and a few misc. bolts. I have most of the bodywork done except the openings for the side pipes. I ordered the Gas-N side pipes and they have some delays also. They are saying 12-16 weeks and I am approaching the 12 week point this week.

[Fordman114]

Mine is 9964. Have you decided on a painter yet?

My serial number is F5R1010328RD, so does that mean mine is number 10103 or 10328?

[egchewy79]

10328