Hi guys, 

We are participating in the shell Eco marathon competition where we manufacture fuel efficient cars.

Due to rule changes for the 2019 season, we are now required to have a door on each side of the car. So we are now required to make a door on the other side of our current vehicle.

I was wondering if anyone has any suggestion on how we can cut the shape of the door and then put the part we cut back in its place and add a hinge to it ?

The main issue is that if we cut the door we will have a tiny gap when we put it back again, anyone got any idea how we can fix that ?

The body is made from carbon fiber and epoxy resin, manufactured by resin infusion technique.