Fitting in the insulation.

Cutting insulation by hand

Kerfing the insulation so that it bends around the curves.

Putting on the outside skin

Staples.

The front panel is on.

Using a hammer and nails.

The next panel goes on.

The hatch framing is done.

The tail lights will fit into this boxed area in the corner.

Gluing in another rib. No springback in this hatch.

Cutting ribs.

More ribs.

Cutting ribs

Design change. We switched to a rectangular door.

Installed the step and the stabilizers

The inside view of the fancy handle

Birds eye view of the outside skin.

This is how the fender will go on.

Mixing up paint. This is Uniflex 255.

It's a nice day for painting.

What a difference a coat of paint makes.

Especially where I sanded the filler smooth.

Looking good

Other side

By sealing the edges with paint, the plywood should never delaminate.

Paint the wheel wells with roofing tar.

Finished.

Behind the Jimmy.

Installing the taillights.

Installing the fenders

The hurricane hinge is installed