Anyone made new door panels?

[GoodSamaritan]

On the freebie wagon I just got the velour has faded badly on the door panels, not to mention the pasteboard behind them is warped and generally ruined from rain. (3 windows were partway down for at least 2 years...)


I was looking at one of the door panels and thought about using the pasteboard as a template to cut some new ones out of 1/4" plywood. If I could get new material under to look right stretched over the metal at the top it might make for some nice looking door panels.

My question is this. Has anyone tried this, and if so what problems did you run into?

G.S.

[hemihotrod402]

if you find anything out, can someone tell me? I need to redo the carpet on mine.

[GoodSamaritan]

I was thinking about using new velvet or velour all the way down. Nothing but the armrest and maybe a new pull strap.

[Enigma]

The problem is that damn curved pasteboard at the top. It would be tough, (but not impossible) to curve plywood to that shape. If it wasn't for that, my panels would already be recovered. Two other options would be to use a sheet of aluminum or steel as that would hold the curve at the top, or make a wood form and lay up some fiberglass to use as a base.

[GoodSamaritan]

Maybe I need to look at mine again. I thought the curved part at the top was metal...

[87gtVIC]

Maybe I need to look at mine again. I thought the curved part at the top was metal...

I think you are right....Here is a link that i was following at one point in time:

http://vb.foureyedpride.com/showthread.php?t=79680&highlight=door+panel

[GoodSamaritan]

OOOh... Thanks!

That's the sort of stuff I was looking for!

I have to say it looks like his door panels turned out really nice. Of course he reused the original vinyl though. I'll just have to tear one of mine apart and take a look at it.

[86GmLsCoupe]

The top part is metal so you can certainly swap that over onto the new panel. I've been thinking about the door panels for awhile and I'd like to try something not moisture sensitive like metal, or even some sort of plastic. Perhaps a piece of aluminum in a similar thickness as the old pressboad with Dynamat Extreme on it. Luckily, my trunk is the worst of it in termas of being warped.

[hemihotrod402]

actually this helps me a lot. I just need to find some of the carpet the resembles the original. Who knows, when i get bored this weekend I might try it. Ive got one to practice on first (off the new door) before i try it on the good ones though

[85crownHPP]

Being made out of rigid plyboard might make getting it on and off a challenge... I pop a lot of door panels at work and they all seem to need to have a little give to them.