1993 Lotus Esprit Sport 300 Turbo

Sorry for your trouble Mitch. This is looking like a monster. I'm interested to see how the pilar turns out, good luck.

RetiredMike wrote:Paint and interior look great.

I put my flocking through a kitchen sifter to keep it fine and fluffy.

Thanks Curt. Do you sift it before you put it away or before/during application?

I decided to share the images of my mishap. Its been a less than straight forward repair. The piece that broke out of the A pillar glued back in with very little issues. You could barely even see the cracks. However when I test fitted the side windows there was a 2mm gap around the top front corner about 5mm going down the A pillar and along the roof rail. And the windshield didn't fit well either. I decided to install the windshield and use it as support for reattaching the broken piece. I figured if the windshield fit nicely then the side glass gap would go away. Nope. After everything dried I tested fitted the side glass and the gap was maybe a little worse. I took the windshield back out and removed the piece for the third time and installed the side window assembly. After that was dry I test fitted the broken A pillar piece and it wasn't close to fitting. I had to sand a mm off of both ends to get it to fit. I then test fitted the windshield and it only needed a little filing to fit. Bizarre...
Anyway I got it all lined back up and I masked off the side window and puttied the A pillar and the roof rail where it had cracked too.

I have it primered and the first coats of color on. Hopefully I haven't ruined an otherwise successful build.

I must say, this is an astounding repair job. It's things like this that makes the hobby worthwile.

On a side note about flock. I used to have nothing but trouble with it until I started using very fine felt, the kind you might find in jewellry boxes, less messy and makes you feel like a proper carpet fitter when applying it.

Well done Mitch. Thanks for sharing.