Rear Window Garnish Molding Fix

[rspears]

When I did the interior one of the things that bugged me was that my garnish molding on the back window was visible from outside, and over time it that back "wrap" had settled a bit on one side making it just "Butt Ugly", and something had to be done.

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When I did the "wrap" panel that fits from door to door, around the back at the window level, I simply used the garnish molding as the pattern for the hole in the panel, assuming that the molding fit the glass. So the first order of business was to make a sturdy pattern of the glass opening, and see how the molding really fits the opening. I guess I could just stick the pattern in place, advertising Free State Brewery in Lawrence, KS but I like to see out the back window, small as it is....

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When I compared the garnish molding to the pattern the top fits OK, with one spot near the driver's upper corner that has a slight gap, but the bottom is obviously arched up more than 1/2" in the middle.

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A yard stick shows graphically what the biggest problem is, but unfortunately the pattern of the glass opening is not exactly flat.

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I think the solution is to cut a piece of 2x4 to the exact shape of the bottom of the glass opening, round off the edge a little to mimic the inside of the garnish molding, and then use that as my "form" to re-shape the molding with some fiberglass mat & resin. I'll make some cuts in the vertical part, leaving the perimeter portion in one piece but flattening it to the form with some clamps. Once the bottom edge fits the space I can build up the spot in the upper corner with two or three layers of cloth, smooth it with a flap disc in an angle grinder, and get it ready to be re-covered in matching vinyl. When it all goes back in there will be some fasteners around the window to keep everything stable over time, and hopefully looking better.