DIY - door panels (1 Viewer)

Joined
Oct 21, 2008
Messages
284
Location
brooklyn ny
Hey guys, I needed to replace the warped, rotten door cards. Here is what I did, perhaps it will help someone.

It started with the need to replace a blown door speaker. This lead to the discovery that some genius glued the door car to the door after recovering the cloth section of the door. I wasn't going to be the DPO on this one so I opted to take my time and do the best job I could.

I order some 1/8" pvc panels on Amazon and some replacement stock-style door trim clips from ebay. I also order some speakers from Crutchfield. One thing I wanted to try was placing some tweeters high on the door. It was important to me to keep the stock look so the tweeters fire through the cloth. Yeah, they loose a little high-end, but who are we kidding it's a 60 with a header!

Anyway, hope these pics help tell the story.

~ Carl

Crappy old card

3lAvi8byly9QAkEQUhTCykEnn2Q_9_x2QwF70NCSfFlRoFUGRy_pvbEOUfDWrfNqw37Pfu_F63vYaYMtvV61jXsbkaKc_MMgbjI5aeqzPcNJINtgqJg1s5aEyJ0tMDMp6vaOPAiIsmbyR1Jqvm_Gxxf0_kQ-fMEGBznmyVeUffFG27IzaTm0d2EPjGTHNGg7Yt6MQ57LLVbTToMZFdeTOBjj1aLpWKe3VhjJugKR_ri4fdaYdvHvg3g1ijg6CEjAdiWngFisDY2lwRYu5HuSuR5ej6gOmBtz5SxluJ2ywvIUGsrrjozwRhudA5hztJG25mCpjf-PpyCzYMV2YOwd2Rtoo1WtofxTozFSnT7fiZn7Q2YD4r2bx2g6eq7G401JLFU-VApYSIhiuO-2g9uBqjEYgcTiv117NP_1nWy_xPVh-Y1dWsYBK3wcQaH5JKI7bIYH2bsol9PYfcb4VNJWtijp-vmc-vkuIUVWtLa3nHnTz0mYVzdrs9qxqEt3oAHUXzBoCvoV2Ky8xnA7on06WRgZLQq13fFbNcVEc4txnViS0EF63PImENir7mxa1bMlaMdl7LXhYxvX69A_Eb7gqwcDMwUTx5t4mWoR0EqNnw=w1588-h1190-no


decent front

WlfIjssHGlXru6-uRSW2cBJQFoUkdvpyx-n8mn-Xux48uMbTiqug8Qm24ZTtvUzvnUffyuBId0nc1_USd9kdZ4GpnNJh_livIrNijrd2WQFUKE0nIZUorgWvfQ4XrIKyrpVZ_Z7TIcf0eH1pnrlgclPo8LuQr9ya9wEOamk0VFumNLwFHN7RsxSIncHO-3FujNoCHU-M4hljF_rCWgJLb6xP03Vs2MgId46tme0HgUXD1aVjBupu8NJLjtETrQzSxT7YJZq_ROyc05AOF_mxcU7cyEPOVxaG2X1L4DkfDPmMkk4J3Y6Zq8xP1FN_LZPZ79OqvJv1xVoy6iHZFDlJgzevZAsxWGfCw9i0AlPLqXEW-tvqxmQd5ZD4K8ugp3rHxLl3fBVgW5XQogL5uaqOWhFjvAIybDoYSky8U_daVEoHwLdtMSswummHGKCQN502Ou7xn6cLzmvATtQI55e3nkUx3J7x5Vhd8F16sTltBoUxGxw_XGAGy2v4Rrm_unEu0NBvo8fHTXbJz4V6Ejxje9KSGCn4kBZyS1AmqsL97Sfmknf8WKWBAI_gsdGRz_XHL-2hYkM-jZTKiUdXHBHEcI9JkhCIW9KaCDphYMbWuQ=w1588-h1190-no


Two sheets of PVC taped together and one of the stock card SCREWED onto the PVC to keep everything from shifting.
iJMscN3VfU04r3puDyEJrrhF6_O3eOm1mepW45PhHo1RKM7O6T-eX_U2Rj35sRepRG7hB_e8c_RWOgJvgohOknozDPuWSYZgXRJNpmCwgCQDhpshe2Jsssc82zhAxASbv03JJHI8CuYlThjutkYggmPq5nFUVLiFZrDy7fJLsf014yxb5OYsl_oesOOwYvqLNdCg415rAj1DyjzoC9psl2FDNvs7HPB-kK9aPdhh5joGbPIw9w1KbI1warMDOJll00PC6ieDxbaq2ed6t2BepLKGoP9yz5ns1BroaN4gHySwFHvQt50QvXG-IPr67PoUcGmDdNA8iBykc2cjdTPWbZhz1EZsS4JCWe--Qr7PpZBHKCK5ZAf2eL8jHIgc-Ron8i2EFCfWyBiOaedtG1C9P_M_bzu_cE9f_gIxBtnrhbOp8vtYuVaemUO6MArb-MPF_UGpbn3Uk6VxwPO9d1o_9170XOndJT2VuErEfeJtuQPrKLAmI9Z_-ci406zoiu76_LGkXUhB17gC2S6JvITgTcfiOY0awQS-jb69Z1hpBWcE7Ln7MMAzHnIvW4BYIUkOmxcfU41L7k3VoCJLg0USQDoFCGFbKWw0v7xDlv2mtw=w894-h1190-no


Using machinists transfer punches to mark the holes

wD56ZdXhYSDsjckHnVAMvf0uFP3VRH1njPhw7KxWIag6GPUsgVvtyrb2HeBpYw5efl44obMbo7nb1seAjpNLlbkawhbiw005GuP3_OGUMvzb9-Su5g6o7W6qBMdPyTNNFkP_20ZcW4qoNffqWxMXYCSIjZOLlmausqM6sol-wQQpy6cfaSD7xeGDpJtwrysxvcP4dE9i8fIJjkg1nNc1PTdKFMk8Obf6F-dzbgwcL_OQ8GjEhEwviisYBdjfiCpVJo2kygENOTW-3AzygjFQbnSwXTSCj3NJXPDMtqd0WT4c5z-rMiy9ehlZFDmVLDgt2q9gb5LZ8siTr9ZR0H8nhnnAvJQ4o-404bCGgZ6OTw5SJVUmoOtFbrE8Jc2NOZUT7WUj36mF6r6KTjMbYJJ3d9xqgQtWHZf6yZR7ALtoMHsBK_ffB2ZJRYic1tOx6Zf08s5biQDUdX7vzqeQX-R5Aa6UTqJ_aADriNqmTknplL_CzvvrG_LTQ6ySaJYEoyb1slHzguiMR5-9z_lIQ9IO0lTJ_ejq3P8hOo4XAjQTIxcSL2aNJKlm0Wti07XxKReAW5xIgI3wN5fGNcnV94chjb0vLkcGLCpmYPrJ9axHrA=w894-h1190-no


After drilling all the holes on the drill press and cutting the plastic on the bandsaw. This stuff is soft and could have been done with a jig saw and and hand drill.

llFiBrQO3qP0s0LBqJx_FVe86wBntcrj8Jjo-eYA1KcD8B6i8l0yeRcLdlWArcuGb5l2Xjt2HM5cb1JQWBFXSry83rMIe66llBqGqT6jcj-BjzeXShYB6QtCRSJy6vDlvr9Cup3wDHhTyNtwYq7imiFNHQf9JVU6N6BKL2w_hq2Wfly3VD3lCHVjYEb_WpDpT2yrTNXRg8OYH1U3QB7241OTWb1mAY6hlhi3tZe8TZgEVT4BLo8c4WzvaP8P__1s8Q__d3CpF5T201_Be3mw7lC-Ufeht4yQrOJcrpo9U31reEb9kXjwTiFLyOqk_GOT4kZ0cklJ5DOekcVEAbzGxkxx7nqxRgHV82m_nc5Hl77zIlcYcUxcs12MsBHYeTALuARe7I20yRbkvpJnn8iguixhNv73bdNRVbs1e81m0smPH4-ygIawtQqqFNThPrNSPFSiQM4OxmdXz8Dm9F90pgdh4akn3S-vEJrALJqp9df3RLWBcmDy69YtSevRwh_ByU6ghw3dXkIn4-ll8qmMg6e_3C1StI9blxeVv5BWZkhrs-_itB13W9GKXqeSwPfvKE-U5PW_Ob7FfXnXggnvfC1SK_8nKq1_-8k5FmdrXQ=w894-h1190-no


Next, after separating the two halves I cut the slots with a jigsaw. I also glued the tweeters in with some silicone.

NAXy45pECPe3U1wYxhrxIUFeHcSWeI4fz6bGIPexrHwsOagfmYqtJR0zFRFLciHT3g3GnGB5YciueuXXtF9SYZoXcSyO_Q6PvlQ6SJFZbA9sG1W8gfecw_EURvqFBJ1toon-KBPRSs-c5ROx1QwfuX8WRnZ1U9NfwW9Y-QV9_BA5a3Zv6pUQ5el6zi_iSY7TDJyISiv9K8k5b7FpShE2g6Pu6UDCSsQ_GWFUBD01jnfUGUFrMnUZTTmAPrjYI8Pzm_RFWuYCV2BHaND8fV2RaU5jBvPEuQStP7dFDXnXxpj8Vp6fjZ9zhA53VtlwqpT6ZK7_QLB_xIOdTsY1L1lpBtlmeseyx84HIdGZX3Os8yRCdCCNEKomYXqFCPQ7q7Rk9vGJlTupnxdpZFCZ1CcDgt_2g8qcXKMZLgjoi2QxcAg25IsARURtg81nCVm-gZHJ2R4S9HMKrmpSSfm43N8zbECI9dKIWFaAXC-FWqlGmU6z_6bIbQ7MHilPhNs6c4QOKjbQG5xD3UudpeNEnag-CqUpjiFDXKQqgSmVhbppB6RTqmA4Llnv-EQ2OmqNzc7BebX_qDXkKYWVEtkLp2FvNEGF_DOQmQR6UQaRl8VZtA=w894-h1190-no


Here is the back after the cloth was reattached. Hard to see, but I attached the stock metal part at the top with some short screws and square nuts. Between that and the map pockets the cloth was pretty tight. I only used the duct tape to keep the ends inside. Yeah, I know, duct tape is lame.

k5mZojfLC2Grr1n2V7lcmw4x-eulezz6mTCEzCk0hrqzuETmeNEOp3H0LIrTjv1cpv105lGYpaRzINK6sZtsbxyvFV7uu4HWCPUsPXmdC4L6D5Ds8qPBvursVGUlsvkL2pIfTFcWHgE1TBCEoYua4sELwkJcgxCNYLVrQyFneZzampF0MBWytKDv7j4x-NmUhOu5sMT3st5x1a2gexJVuARPYd8OU3QyZG2zBmRCrHaZ-pe2rOOodT8ijDcX_lTtM644zVu7MhTZnjx8Ft2FsQDIWPlFz_DsrAb7Wp7QEQ12Ri0RNMCXT51IDhxSweinAqjL4kXtBdrZggq84Gdet9xJzToUz2cQRaJQ_vtbs866RtZ_mR7-TK3sP8KqdKWTzthKefqy-SfnZ2BBuXl6YWFRysKcuF8v9-q_iYg8I1zWIjNRF0E9EMCQu4RBEl5KNZ8ejD5R162MU7bWD2KqioX0yl4yhG6WmTUfBU-CEpmM0mBczYsQikWTTvpz5CVvPSZcY2zCJga78goDw5y5AJ2gTAKZZWt25zVfsSIH4nAhhWC2TEojZ7eK3EIAt7koOjpTHyJTVwR6hhvBPocu0X9oYS5RTb6BLdWO6b2cag=w894-h1190-no


Here is the front. The tweeter is right above and to the right of the window crank hole.

hZbl5ZMuzqo0C5hiBd8AL6W6nBHvE79JTRhataYwhE5UXac4fI6PoQOazVQGxFtCHPa2FNiuEBdZ3AsIwjVbrP99GbzTG2m5SUDrKEeqHzs2ysxPLqPDIOP-Urq5Y5R1c4KQGpt0lpNiP9-5RmS3LSc_0RI7cBc_lkEPF-4aEBQRLsIoFz0E9VGzH1LvJ9z961qn8PdpnYZ4e8Dt1Ls7RgFnsIXYeZYPjOLip_1Wc9IAGjsuAnVh6hwHoUWN_r1kwNwvXsOO4zrRUG4kaNIaCv7_KcZNXVDH-K3oPm6lZ_7sQIesrb5yyno1X78sVSI0vnnSUHGwvd1oPS-Xt_7MrJCgjXPuXWbAo58xWFvTXebxmFP23XX00SZqtPKljMp-neGSybkvx7a6DaE_F7Mv2vDDy7Y6U_CYPY0o8TY71Jj8HztENc2FxQmfrPED5FrmxwtufRTnmgZkpHm11F8f4FqdEF8oHRqjgadA17dsW-vwIvmP7yWgz5HNA1xcGywyD50EudKQy913LtIGdUYlfW_GnkEbX6vD9T2tkyX94p3DmA9-ZHvKOf5mpUU2kyWzqjDG1e3fAKmP67Mn2RnR-oHJIKNKdQvWiLbmkFpjpg=w894-h1190-no


And here is the finished door in place.

zNlmwYGDQENOCoSX6kk7AhdgWqcofWLPthPKiXj4xWnlEUA7tcUOg6QepiNqnWq-NqUxITOrPfVPPhBIHDZY25b_IznEEtvNisxX6NGoaWYbyIcuiINPU0vTstxhAYF4nbmcD4KBiPYl_CBFxihaCyaG9VUeg5LF0Jocgbj2unTzd1n1KXXd86lppWpq3NnQ0IX05dKDDyBrf3uaew93-VU1DEp478HEkeG8o6ea2ZKxRVp2rzHilGO1DuqWjZS_BpCy5MzzJ2YrOPEzgna9RM6reoLCpvXnPdx9V0440M0SCvgQGOcOq24Y0K5earUJDSRI7_sEOKPIlxSHzweh7Ofbf65ivhjqlkDhyf-Xt8Q4AHeF7InYp7Y51_xKkrHYOIA1AsyYLm-V8gUwuEXYPg5PqK5I2zsGU_99OyA2ubQ3Ub_8PdOE16UOqMNnzDyrqhGIoqx7C9QFhSvlTHGPdy0NXE9Y21dj_xp-TYoW9W8az4mfeI_MAqBH3eJrh_YrwQkaEs9YvPc-PlY0QWnRbUIY1eBsH4PxPlFdLO8xapfKzk4sDgvYjBLFIiLKhfyb8LZfjWg_cyJqrJcmP3GVnu6iNQYJIZzqZnMUSMwXEA=w894-h1190-no
 

erse

SILVER Star
Joined
Aug 18, 2015
Messages
1,658
Location
Las Vegas
Nicely done. Can you post links to the materials you bought? or you know if you want to make some more...;)
 
Joined
Oct 5, 2007
Messages
2,023
Location
Northern Virginia
This is why I like this forum. I did this years ago to one of my cars door panels using the hard board. Older age and tons of other information and I have forgotten about doing this and how. FYI this same idea can work for the rear tailgate carpet.
Great job and now I will be doing mine this winter.
 
Joined
Oct 21, 2008
Messages
284
Location
brooklyn ny
Yes, I thought they had been and it was confirmed when I pulled the panels. The new cloth was put on top of the old cloth. That was the extent of the work done on the doors. I would have been pist if I had paid someone to do that work.

Nice job... looks like your doors and seats were redone at some point?
 

cwwfj60

Supporting Vendor
Joined
Dec 16, 2007
Messages
1,238
Location
San Antonio, Tx
Wow! Great work! Love the concept, plus its water proof (atleast the pvc part) Those should last forever....Very cool!
 

Users who are viewing this thread

Top Bottom