OK; after some time to let the paint try and cure, etc., and beginning the build for The King and I set (I knew that was going to get in my way, hence my rush earlier), I started re-assembling this beast.
First, I needed to drill the holes for the shanks in the inner door panel. To try and figure out the best way to do this without tilting the drill, I opted to trace the shanks on the back of a piece of tape:
Then I rolled up a little piece of tape, just to stick it on the end of the shank:
I reattached the inner panel to the door with just a few screws to hold it in place. Then I stuck the shanks through the front of the door, trying to keep them as straight as possible, and using the flange to help with that. When it met the back of the inner panel, I gave it an extra little push and pulled the shank back out. The tape stayed on the back of the panel, as hoped:
A little measuring to double-check and tweak the location just a bit, and I was set to drill the holes. I couldn't have asked for better positioning:
Because I noticed how much sharper the edges of the stainless flanges are than the black plastic ones, I wanted to try and at least buffer the paint job from them a little. I cut some of that thin foam that comes around electronic equipment (TVs, stereos, etc.) to try and protect it a little:
I primed a piece of luan I had laying around and ran the shanks through the door and that, because it flexed to the shape of the door but also gave more reinforcement to the metal of the door. I then started pre-cutting pieces of 1" foam board to fit, including drilling holes for the shanks. I built these up in layers, using spray foam to fill the gaps between and around the edges of the door. I meant to get more pics of this, but it became a race with time as everything started expanding. Here's the beginning, though:
And before I knew what hit me, the whole thing was insulated and re-attached.
While that was setting up, I decided to look at the freezer door, which had one spring that had come undone. When I took it apart to fix it, I noticed the insulation there was more of the old fiber/wool stuff, sealed int plastic to keep moisture out. Great idea, until it gets a small puncture or moisture gets in. Now it was just a must generator. So I replaced it with foam board as well. Here's the first chunk replaced, and you can see some of the old stuff.
Once the foam had some time to set up, I took the screws out of the inner panel and reattached the gasket. Then I got the door reattached (a major pain with one person), and here it is in its final home:
Then I attached the Perlicks and chrome handles; that was enough for last night, and I crashed.
This morning, I buffed out another place that got a little roughed up somewhere over the last week, then attached the chrome strips to the paint borders:
So now the exterior is pretty much done, except for the drip tray. I'll post what I did there in a single post once it's done. Next, time for connections (and beer!)!