Surprisingly, the emergency door handle was ready on Monday, a very quick turnaround and cheap too, at £40!  Work continues on the emergency door window frame, firstly correcting the dimensions of the outer frame top horizontal, which sets the rest of the outer frame’s dimensions.  Next was to cut,  fold and weld on the sides and the bottom outer pieces.  By the end of the week I had finished the entire frame ready for cosmetic filling and had a pplied a preliminary coat of red oxide to the rear ready for sealing the welds.

First job this week was to start manufacturing the emergency door window frame.  On the Wednesday I delivered the the handle to the chrome platers at Ongar. Still waiting for the glass for the remaining O/S window.  by the end of the week I had trial fitted the top outer frame piece to the ED window frame.  This revealed that I needed to reduce the inner depth by 3.4mm towards the glass in order for it to fit properly against the inner surround, so I removed again ready for work on Monday.  This also affects all the dimensions of the remaining outer pieces.

Continued working on the emergency door, stripping off all the old aluminium cladding.  It now fits, more or less and should be ok when the locking clamp is refitted which will pull in the bottom.  The natural tendency for it to spring outwards is probably intentional so as to aid its opening.   I found that many of the  the joints on the door frame had loosened, so I reinforced these either by adding a new screw or drilling and gluing in a 6mm x 30mm dowel.   I ordered the aluminium and the some 5mm dowels for the rebuild.  Whilst waiting for these to arrive I created the template for the emergency door window frame and started to build it.  I got as far as welding the first corner flange onto the base for the rubber by the end of work this week.