Thanks for the tip, Dancam, and ya in hindsight I should have made the pictures bigger, you see I browse this forum on my computer and the pictures look fine on the 50" big screen tv, but I see on a smart phone they are pretty darn tiny. I was mistaken about the DOT certification the lights just say SAE on them so maybe you are correct about needing reflectors... I'll follow up with the supplier.
Today, the clamshell was framed and test fitted for final mounting and weather sealing. Folks, I dunno if I'm just plain lucky or what but magically I continue to amaze myself at what I can accomplish! I actually framed the door well! And I had no room for error - the aluminum pieces were only about 1/4" oversized. I got the frame really close to perfectly where I wanted it, so it forces the clamshell square now when closed. The vertical framing is 1/8" thick 1/2" x 1" U shaped aluminum, and the horizontal framing is 1/8" thick 1" angle. I got the miter cuts to line up really well using a chop saw and multiple test fits. And the clamshell actually shut right into the framing as expected... I was worried I'd mount it too tight and the door wouldn't shut, but I got it on the first try. Just temporary rivets for this test fit, they will be drilled out and a bead of sikka will be laid down first and then re-installed. I took a picture of the weatherstripping in the third pic - it fits coincidentally perfectly in the u-tube and will mount on the aluminum angle just fine too. Its going to make a fantastic seal I can already tell, only worry is that since its bare aluminum on the other side it might tear into the weatherstripping, because its soft, supple, and really elastic but perhaps as a result a tad delicate. I should probably cover the grinded aluminum with hockey tape or something but I have little clearance as is so whatever is done it can't be thick.
Still thats the last tough task in this seasons build! Got about a week more to get this thing on the road, I know so many times I have said it was only a few more days, just a few more days. Well by golly now for sure it is a few more days! And we go the scale and put a photo of the ticket on this forum for everyone to see. Up on deck is electrical, and in the hole is mounting the fenders. I can see the end of the trail for this season.. but still hoping the weather stays nice as I have no choice but to keep working everyday.
The clamshell looks so much better from the side and behind with nice framing! I am so happy with my accomplishment here, just very very relieved. My oh my has this door ever added heartache to this project. But I wouldn't have it any other way! Happy weekend, friends - here are the pics: