Long Overdue Progress! Making New Door Panels 12/8/24

First test fit to the actual door. Some things to clean up and covers to bridge the latch and the power connector block, but very close:
1734560688006.png

1734560881147.png

Frame completed with component placement:
1735671726280.png
 
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Installing Mag daddy door "clips". This is going to work out well since I have to take the panels on and off multiple times. I cut a rectangular pocket first, and glued a thin ABS sheet with a hole in it:

Magnet 1.jpg

Then I covered the back with a fiber sheet that loosely captured the magnet. Fom pad on the back to push the magnet out.

Magnet 2.jpg
Magnet Covered.jpg

Done:
Magnet 3.jpg
 
thats really clever, will there be any mechanical attachments or just the magnets?


Installing Mag daddy door "clips". This is going to work out well since I have to take the panels on and off multiple times. I cut a rectangular pocket first, and glued a thin ABS sheet with a hole in it:

View attachment 57341

Then I covered the back with a fiber sheet that loosely captured the magnet. Fom pad on the back to push the magnet out.

View attachment 57342
View attachment 57343

Done:
View attachment 57344
 
thats really clever, will there be any mechanical attachments or just the magnets?
I am going to have two hidden screws at the front and back plus the magnets. The magnets hold really well, you have to pry them up to release. Also, I reused the top part of the C3 panel that has a metal channel that hooks onto the top of the door.
 
Glad it worked for you!!!

The other thing I would do- is coat the wood with some fiberglass resin. Just brush it on.
It'll waterproof the wood and strengthen it up a bit.
 
Glad it worked for you!!!

The other thing I would do- is coat the wood with some fiberglass resin. Just brush it on.
It'll waterproof the wood and strengthen it up a bit.

I will do that once I'm finished with the frame. It has to be better than the original that was made out of compressed pulp!

Thanks for the heads up on the magnets.
 
Does anyone make a cable barrel that uses a set screw to crimp on (like this throttle cable)? I think I have seen them with a set screw in the end. I need to change the length.

1737759628069.png
 
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Does anyone make a cable barrel that uses a set screw to crimp on (like this throttle cable)? I think I have seen them with a set screw in the end. I need to change the length.

View attachment 57350
A good motorcycle shop that knows anything about custom cables can get them for you. Motion Pro is one of the better brands. This is a small selection from the Western Powersports catalog. They are one of the bigger distributors of Motorcycle parts.
 

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