Jet Jockey/A4 Pilot

First here is the door as it has been for the last month or so. The interior panel had already been removed, so were the speakers and window motor. I forgot to weigh the darn door when fully laden. <b>As is, the door weighs 43 lbs!</b> I'm sure you can easily add another 10 lbs if not more when fully dressed up.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2007.jpg">


Tracing the line where the cutting is going to be done.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-1.jpg">


Close up of the line.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-2.jpg">


The cut out (most of it).

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-3.jpg">


Here are the inner guts of the door.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-4.jpg">


Another angle.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-5.jpg">


An empty door shell.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-6.jpg">


The window frame.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-7.jpg">


After the cleaning but prior to filling down the edges. The sound deadening material (tar like material like in the rest of the car) will be removed tomorrow.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-8.jpg">


The edge after the filling.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-DoorCutting-Trimming-Oct27-2-9.jpg">

<b>So I'm sure you want to know how much weight I saved by this process. Well here are the numbers...

As I stated before the door started at 43 lbs and after the cutting I weighed every part of the door individually and this is the break down...

Door (bottom portion) = 21 lbs

Window frame = 05 lbs

Glass = 05 lbs

Door lock = 02 lbs

TOTAL = 33 lbs

So a savings of 10 lbs! Not too bad.</b>

Evil Buddha

How would you describe the performance change in the car?

Jet Jockey/A4 Pilot

I'll let you know next spring when most of the work is done. However the lighter the better!