Hi. I'm new to the site. very impressed.

Recently I replaced the plastic washers on the driver's side headlamp cover RS mechanism (seemed to be sticking, not, when I move it manually, it's much smoother). Taking it apart was not an issue and neither was putting it back together, however, now the door is misaligned. I took it apart a second time and carefully put things back together, but still not aligned properly. Is there a trick to this? Suggestions?

There's a bit of adjustment in the posts/nut arrangement that holds the door cover assembly together. I was able to get a good alignment by loosening the nuts and 'rotating' the cover then retighten. If you need more you can gain a little where the entire assembly bolts to the core support. A combination of the two should do it.

Thanks RickD Much appreciated!

A few of those plastic washers have a collar on them, and if its not set into the hole just right it can ride up high and look offset. As mentioned, softly snug bolts then align, double check the collar washers are up into their holes, then snug again. :) Arent they fun? :D

I'd hate to add up the time I spent on the RS doors :)

I've got a few hours in mine over the years. And I haven't taken them out or done much of anything except maintenance. Drove the car home from racing it Friday night and had the headlights on. Haven't done that it years. Anyway, I pulled into the garage and shut off the engine and headlights at the same time. I thought 'Oh-Oh not enough vacuum for the doors' because I didn't hear them close after the engine stopped. I got out expecting to have to pull them closed. No need. Perfect. Whew.
Rally Sports are so cool.:thumbsup:
http://epitomesrebuild.com/images/247.JPG

Or they never opened when you were driving home...!!!;)