Suspect I'm with you on OCD scale, may be teaching my grandmother etc but GRP continues to 'set' for a long period, and I do mean long, after removal from moulds hence need to be careful how its stored (no idea if this was problem with your door).
Cars in the Workshop Replicar - 1998 Mk2 1.8 donor Honda Civic Coupe SR Discovery TD5 Shogun 3.2D LWB
Yep, possible it was laid down on the ground or against a wall (before I got it) which would have put some pressure on the screen lip, would also explain the twist as it was much more vertical than the other side.
Probably natural thought process as most people would not lay the door down on the shiny side.
Anyway, all fixed and cost was minimal, all part of the fun building cars at home. If I had paid 30k for a kit I might have had a different viewpoint.
Got my registration paperwork back from DVLA, impressive 8 working days. They even manged to get my receipts back to me.
Plates on order, just waiting on V5 to transfer my private plate.
Then I just need to finish the car. Going to NEC for Practical Classics Classic Car & Restoration Show on 24th March so hope to pick up the final small bits and pieces needed.
1999 60k MK2 1.8 5spd donor 2003 40k MK2.5 1.8 5spd (sold and missed badly) "Life is like a book and those that do not travel only read the front cover"
Will get it powedercoated for a bit more resilience.
Now that I keep the grille, I think I will try an fit DRL’s in the side inlets. Quite difficult shape and size to judge what would fit best and be easy to mount. Thinking CBS 95mm LED’s or alternatively Toyota Corolla ones have nice 4 point mounts with similar profile.
Pleased I kept my MX5 Metex car cover, hopefully keep the worst of the dust off.
Bearing in mind the front inlets (the ones I assume you are placing DRLs in) are round when viewed from front why not use a tin of same diameter and shape into profile like the headlamp surrounds (only on their sides) and place circular lights in base of the tins. You could either use the tins as a mould for GRP or if tins are robust enough use them? (A bit like the old method of frenching in lights).
This is how my fogs lights are to be installed.
I very much doubt you'll find anything that fits the profile perfectly but you could also use the above if you find something close to set units in.
Next was a bigger challenge to make a recess for the lights. Struggled for days to find a suitable size tub to mould off (all kitchen lunch tubs were too small). While buying paint for our bathroom I found these disposable paint tubs in B&Q.