Pilgrim Sumo Door Panels

[Bob Findlow]

Being tight with my hard earned, I have decided to make my own side panels out of ply-wood, rather than buy them off Den. My first attempt has been using ply of a quarter inch thick, however, when I put my door in the correct position on the body, there is quite a big gap between the panel and the inside edge of the sill! I realise that I am going to be covering the panels in foam and leather, however, the gap still seems excessive! Can someone tell me what thickness of ply-wood is used on the panels supplied by Pilgrim?

[Miket]

Hi

In reply to you question, without taking mine apart, I would say that he uses 3/16 3 ply.

Might be a silly question, have you fitted the door seal on the body.

Cheers

Mike T

[agwebsites]

I also believe it is wise to use marine plywood, if you haven’t already.

Andy

[Kevin W]

Yep the gap looks too big!
But as someone previously mentioned, if you tap the rubber seal onto the 'flange' on the body, it'll take upmost of the gap. Once you add the foam padding onto the ply, you'll see there that it fits snugly.

I also noted that if you use screws and cup washers to fix the panels, then there is a gap round the door seal where the cupwasher squashes the foam and leather/PVC. I'm now planning to re-cover the doors using concealed fixings.

Kevin

[graham]

KevinW

Yeah that's what I did on my Sumo's, concealed fixings.

I predrilled holes on the panel and inside of the door and fitted tight fitting countersunk screws on the wood (with a bit of glue), then covered the door trims, then plac into position used nuts and washers on the inside by putting hand inside door round the back and tightening (fitted map pocket last) Current car which is SR (body is early Pilgrim as you know doors are thinner and access is tight so same method will be used but using plastic trim fasteners they just push in the holes and grip.

Graham

[Kevin W]

Thanks Graham, I'll bear that in mind.
Kevin

[Bob]

On the subject of doors has anyone got a good idea for finishing off the ends of the door windcord. Apart from the orrible bracket that Pilgrim sell. Paul Hardy finished his Dax in a very tidy way but it involves welding stainless anyone know a simple and effective way.

[Kevin W]

I'm also looking for a solution. I've got a pair of the Pilgrim brackets and they are indeed very ugly. I bought some Moggie minor finshers - look great, but fixing is wrong way round, so won't fit a Sumo.

Kev Wells

Just use thicker door panels, or if you already finished them, do it as I did!
I glued some rectagular rubber wires 10x20mm in the back of the panels - you can adjust it, and it looks good.

JUST TAKE THE RIGHT GLUE!!! (shoemaker helps you!!)

Gerd

[Bob]

A bit late now I know but I dug out apicture that shows how tight the rubber fits to the door. I am still looking for an easy solution to finishing the rubber I have good long term solution but I dont think I can make in time for my SVA.By the way I had my registration inspection yesterday. The inspector was very non commital and would'nt say if I had done enough to keep an age related plate or get a Q plate. I will have to keep my finger crossed.