I don't understand why the pics aren't showing? I'm using photobucket and posting the IMG links just like I would on any other forum....???

What % MEKP did you use? 

As I would make a guess, you have some places that are thicker than other... when curing there will be an exothermal reaction. The more material you use the faster it wil cure, the more heat will be created, I think this formed some shrinkage causing it to be ripped apart in the thinner spots. your pictures are a bit difficicult to understand btw

Matthieu Libeert
Founder MAT2 Composites X Sports
website: www.mat2composites.com

You used a gallon for a door?
Unless it was for a barn I would have thought that was rather a lot.

Brian.

same here those places that not enough gelcoat get same thing like you got or wrinkles.

Thanks for the help everyone.

I agree that the uneven layers was likely responsible for the cracks and pull away, HOWEVER, I used 100% silicone caulk in all the small crevices between the glass and the weather stripping. I have read that silicone can contaminate gel coat?? The area of lifting is in the same areas as the silicone. I have ordered soft fillet wax for a future attempt.

I am so tired of failing at this...I'm also doing this in my garage and I am at the mercy of the weather((((

Here is a pic of my door flanged prior to gel coat...you can see the silicone caulk all around the seams. I'm worried now about silicone contamination and if this will cause future problems.

Silicone is very very bad! It's like teflon, no liquid resin will adhere to it and it wants to creep away from the silicone due to its surface tension.

Hit your reset button, watch the excellent instruction videos on youtube again and start over. There's really no point wasting lots of money and material on full sized car doors, take a small worthless object and make a mold of it, testing ALL your materials and procedures. If you fail, start over and correct what went wrong. You will learn more from 10 failed small trials than from one failed big attempt. And maybe the eleventh attempt will result in a perfect result. Only then should you consider bigger projects which might cost you lots of invested money and time.

This is a journey. Every journey starts with a few small steps. If you fail only one of them you won't reach your destination. So make sure you take those first steps properly. And on't take shortcuts because you might end up in a dead end. Others have walked this path before you, follow in their footsteps. Don't try to build a bigger, better mousetrap, just use one that is proven to work.

Yoda - out...