I decided to make door skins for my 77 using fiberglass. I originally wanted to reproduce the entire door. The windows and door openers would not be that difficult but I don't think reproducing the door latch would be easy. The plan is to make fiberglass molds from the doors, create the part from the mold, remove the door skins and replace with the fiberglass part. I have both doors off and have striped off the trim, mirrors door handles and plugged up the holes with bondo. While doing that and measuring the contour of the bottom I realized I had uneven spots and I can't figure out whether the low spots too low or the highs too high. I can fill in the low spots with bondo or pound out the highs but then I take a chance on it not matching up with what it originally was in the first place. I guess I'll have to find one that's perfect and somehow measure the angle or install it back on the truck and see how it looks. Its not that bad if you're at a distance. I used a straightedge and a drop cord to check for levelness.
They're not that bad. There is a natural curve to the doors anyway. I got most of the rough spots smoothed over and mixed up a quart of Duratec Sanding Primer which wasn't enough to do both doors and hood. It looked like rain so I decided to wait till tomorrow to put on the 2nd coat.
Yeah, I'm doing the hood too. I just ordered 15 yards of chopped strand mat fiberglass for the molds. The big challenge is going to be removing the door skins and getting the fiberglass to attach to the metal. I have an album where I'm posting the pictures.