I've seen similar door panels in other threads and on other rigs around the interwebs. Figured I'd give it a shot as mine were starting to crack and I needed to replace the exterior door handle anyway.
I started by taking apart the existing driver's side door panel. It has more staples than it needs holding all the soft material onto the chipboard "frame". After taking it all apart, I took the chipboard frame to TAP Plastics for them to use as a template. I bought a sheet of 1/8inch black ABS plastic (common material, any plastic carrier should have it) and had them cut out the outer shape since I don't have the proper tools at home. If you plan on doing all the panels in your FJ, it's more cost effective to just buy a good tool for the job rather than pay the $20ea for getting the panel shape cut. They had a one-day turn around time for the cut work so I picked it up the next day. They did a good job and there was no melting or warping of any kind so if you would rather not deal, maybe the $20 is not too bad.
Once I got the panel back to the house, I drilled/cut out all the openings for mounting hardware, arm rest, door handle, and window crank using the OEM panel as a template to line up the holes. I didn't cut out an opening for the speaker as I've removed mine. Later, I learned that the OEM panel sits about half an inch lower with all the trimming than I would have liked the bare ABS plastic panel to sit. With all the holes done, its just a simple matter of slapping it against the door and using some plastic push-type rivets. I ordered mine on Amazon. Not sure on depth but the hole size you are looking for is 8mm.
I'm very happy with the minimal feel and I like the exposed door tops. Gives it an old school vibe inside to see exposed, painted metal in the cabin. I still have all the other panels to do and I've already decided that I will circle back and redo this one so that it sits higher. Also, all the original door hardware (arm rest, door handle) don't sit flush against the now thinner panel. I'm trying to come up with a clever solution for this but if anyone has any ideas, I'm all ears.
I started by taking apart the existing driver's side door panel. It has more staples than it needs holding all the soft material onto the chipboard "frame". After taking it all apart, I took the chipboard frame to TAP Plastics for them to use as a template. I bought a sheet of 1/8inch black ABS plastic (common material, any plastic carrier should have it) and had them cut out the outer shape since I don't have the proper tools at home. If you plan on doing all the panels in your FJ, it's more cost effective to just buy a good tool for the job rather than pay the $20ea for getting the panel shape cut. They had a one-day turn around time for the cut work so I picked it up the next day. They did a good job and there was no melting or warping of any kind so if you would rather not deal, maybe the $20 is not too bad.
Once I got the panel back to the house, I drilled/cut out all the openings for mounting hardware, arm rest, door handle, and window crank using the OEM panel as a template to line up the holes. I didn't cut out an opening for the speaker as I've removed mine. Later, I learned that the OEM panel sits about half an inch lower with all the trimming than I would have liked the bare ABS plastic panel to sit. With all the holes done, its just a simple matter of slapping it against the door and using some plastic push-type rivets. I ordered mine on Amazon. Not sure on depth but the hole size you are looking for is 8mm.
I'm very happy with the minimal feel and I like the exposed door tops. Gives it an old school vibe inside to see exposed, painted metal in the cabin. I still have all the other panels to do and I've already decided that I will circle back and redo this one so that it sits higher. Also, all the original door hardware (arm rest, door handle) don't sit flush against the now thinner panel. I'm trying to come up with a clever solution for this but if anyone has any ideas, I'm all ears.
