One piece Suburban rear door build

[tygaboy]

I'm going to build a one piece composite rear hatch for my '52 Suburban and rather than include it with the rest of the build, I thought I'd post it in its own thread. My 'burb build is here:
http://67-72chevytrucks.com/vboard/s...d.php?t=249457

The process I'll follow will be to start with a set of clam shell doors, make molds of the inside and outside of the top and bottom, bond the inner to the outer to make replicas of the original parts. Then I'll bold the top and bottom parts together to make the one piece hatch/door. Since I'm starting with less than perfect parts, I'll then need to bodywork this one piece door, fill unneeded gaps, etc. until it looks and fits the way I want. Next, I'll make a mold from this one piece door and finally, make the "production" part.
The goal is to make the entire door weigh about 20 lbs. I may use carbon fiber and honeycomb core to get the stiffness I want. We'll have to see. So, let's go:

A fellow Suburban enthusiast had a spare Clam shell rear hatch/tail gate set and loaned it to me so I could make the molds. These are in OK shape but since I'll have to make it all one part and do a bunch of bodywork anyway, it's not a big deal that these have a few dents.
Here's the top hatch. I taped up all the hinge and latch cut outs since I'll have a custom set up for all that.