Last work session of July-2019, so I better make it count. I sanded the door to a nice fit and then cut out the underlying lip from the scrap HS skin. The first one was not to my liking as it was a bit small - so I made another lip that fit better.
Then it was off to the scotchbrite wheel for the final sanding/smoothing of the storage cover opening. I felt like I was being careful and smoothing it on the trailing side of the wheel but all of a sudden there was a loud "BANG" and the cover was out of my hands and had been slung under the wheel. That's why I always wear the safety glasses - even when I am being careful - since things like that happen in a fraction of a second. Well, the cover had a wave and some bends in it, but it wasn't in too bad a shape. The wheel was another story.
I spent the next 30 minutes or so un-bending the cover and it came out pretty good. It will likely be fine as there is just a small hump in one area and if I don't like the final product I can always re-do it. I also drilled a few lip rivet holes too close to the open edge - so those will be filled in with the Rage filler. There is plenty of meat to hold the lip on, so I will decide if it passes the "look test" when I get the hinge and lip riveted on.
The last chore of the evening was putting the new scothbrite wheel on.
lip clecoed in, door taped in place
slightly bent frame at this point - see the waves in the lower left corner
