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Level Motorsport M86 Build - Rocco

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Rocco gets ready to notch a door bar.
201 / 815

Rocco gets ready to notch a door bar.

  • Rocco gets ready to notch a door bar.
  • I mark my notches by eye with a sharpie. There is an intersecting line for each end of the tube, then the angles of the notch. After the rough cut material is carefully removed until the notch fits, then the process is repeated on the other end of the tube. The intersecting line is good to have because it can be used to measure degrees of rotation and to make mirror images of your notch on the other side of the car.
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  • At this point we are close, but need to file down the inside of the pipe to get a clean fit.
  • I use the belt sander to round out my flap discs. That round shape as seen in the photo allows me to make cuts to the inner surface of the notch that are more similar in shape to a round tube.
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  • After precise fitment is achieved, the edges of the notch are beveled to the thickness of the filler being used (in this case 3/32"), this ensures that the weld correctly penetrates the notched tube material.
  • Careful tape placement will help when the gel coat is put on, preventing deformities where the panel has holes.
  • Remember we talked about the panels being molded having a perfect finish? We detail all of the panels like they are going on a show car before screw them up with gel coat and epoxy.
  • They carefully clean and wax the panel to remove impurities before adding the gel coat.
  • The thought of creating a mold that has all the proper holes for door panels, wires, speakers, and the window regulator leaves Dan unimpressed.
  • They start filling the holes with clay.
  • Morbidly obese fingers come in handy for obtaining a smooth finish on clay.
  • While I play with clay.
  • As components come off the car they are weighed and a tally is kept. This helps us keep a running tally of a predicted final weight, acts as a reference for future builds, and is essential in calculating unsprung weight so that we can have a good starting point with our spring rates, suspension setup, and aero setup.
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