The results of the failed attempt to use Boelube as a release agent. The Silicone stuck to the Boelube covered firewall plenty good … better than on the door actually.
Looking at the edge of the hinge one can see how the door bent adjacent to the hinge while being pried off the firewall.
It took quite a while to remove all the silicone from the firewall and cooler door. After cleaning the mess up, the door was placed on a back riveting plate and a piece of wood and a soft faced hammer was used to reshape the door and make it flat again.
Cooler door after being reshaped to lay flat again.
For the next attempt tomorrow, I’m going to do what I was going to do in the first place and that is to lay down packaging tape onto the firewall from the hinge outward. Then the packaging tape will be slathered with Vaseline and the cooler door closed as before to let the silicone cure. After curing, if the door does not lift freely the packaging tape should still be able to be peeled away from the firewall lifting the door with it.
Firewall in the area of the cooler box from the door hinge outward is covered with packaging tape. The tape will be coated with Vaseline for the next attempt at making a door gasket.