DIY Door Panels

[haze1964]

Decided to make new door panels as mine are warped and torn. Was going to post once I was completely done, but would like some input. So, here are my notes and pics from the one I did today.

Went with 4x4 sheets of 3.2mm hardboard (Masonite). Using the old panel as a pattern, I drew the outline with a sharpie and cut the shape using a jigsaw.

I put the old panel over the hardboard and held it in place with clamps.

Used a marker to outline the larger openings. Left the old panel in place to drill the smaller holes, including the cutouts that secure the door clips.

• For the clip cutouts, I used 1/2” and 9/32” drill bits.

• There are two other smaller size holes, but can’t recall what size bits I used. Pretty easy to figure out. I’ll update when I do the remaining panels.

Once all the holes were drilled, removed the clamps and set the old panel aside. Noticed the holes on the backside of the hardboard were not uniform, so I used a razor blade to clean them up.

The center diameter of the clips I used is 5.5mm. Used my jigsaw to remove a little material between the two holes, and then used a file to open the width of the channel to approx. 5.5mm. Sorry – forgot to get a picture of it. I’ll add one when I do the next ones.

Used 7/8” spade bit, 2” hole saw bit, and my jigsaw to make the larger cutouts.

 

[haze1964]

Can’t recall who on the forum recommended the clips, but here is a link:

Amazon.com: 25 Toyota Trim Panel Retainer Clips 90467-10188 Sienna: Automotive

They worked well and snapped in without a problem. I have a little cleanup to do, but pretty happy so far. I spent about 3 hours on this, but think the others will take about an hour each, now that I have my tools out and know what I’m doing.

Still have to cut the speaker hole, but haven’t decided for sure what I’m doing on that. See pick below of what the a****** PO did to the doors. He butchered the bottom as well as the bottom half of the speaker ring. I welded some material back, but not sure how sturdy it is.

So, my questions:

• I want to treat the panels with something water repellent. Any suggestions?
• The Dynamit strips inside the door are old and are starting to peel. I think I will strip it out. Any suggestions on a material or paint that would help with sound and insulation?
• Any suggestions on mounting a speaker would be appreciated. All 4 doors are butchered in similar fashion.

Thanks for the help.

 

[dirtyboots]

Sound and insulation:

Making Vehicles Quieter | Sound Deadener Showdown

Lots of info and a long read, worth it IMO...learned a lot from that site about vehicle noise

If you're not to confident in your welds there are some panel adhesives for non structural stuff that is pretty amazing. I have used a 3m panel adhesive and it is amazing how strong it is. Might be an option for adding support to the door.

 

[mmajsw]

Would a few coats of Thompson Water Seal work? The wood is not getting full wet in the rain outdoor exposure. At most it might get some condensation and humidity.
Alternatively, a good paint might be all you need. But those are my initial thoughts.

 

[SUMMIT CRUISERS]

As mmajsw mentioned, I would waterproof it and also install a heavy mil visqueen (like OEM) and or sound deaden it as well.
Looks Great!

 

[Hornd]

Nice Work!
If holes are backed with a 2X4 or similar when drilling holes will be cleaner.
Forstner Bits drill the cleanest blind holes
A Spiral Bit in Dremel or Rotozip drywall bit would work well to combine the fastner holes quickly.
Once you put that panel over the door no one will know it's chopped up below.
Might want to stretch sheet plastic and caulk let dry, trim, then install panel.
That protects any moisture entering window from ruining the panel.
Are you going to glue some vinyl on panels to make them try to look OEM?

 

[Wayne]

Great looking work! Bummer about the sheet metal being cut out.

 

[Cruzerman]

I've heard that the plastic sheet that goes behind the door panels are available from the dealer at a very reasonable price where making them doesn't make sense.

 

[Geert]

Why on earth would someone butcher the doors like that??

 

[Wayne]

The plastic vapor barrier is available through Toyota, it's about $12, and the one barrier fits both sides (one part number).

 

[aae42]

i need to do this to my rear drivers door... the door card is all mangled

 

[IanB]

Why on earth would someone butcher the doors like that??

I'm guessing the truck had a big stereo installed in a previous life.

Nice work on the new door card!

 

[haze1964]

Really appreciate everyone's input. Some really good ideas and tips. I'll post some pics when I'm finished. Thanks again.

 

[landcruiser80]

Looking forward to the finished product. Nice work so far!

 

[Locked79]

Looking forward to the finished product. Nice work so far!

X2. Can't wait

 

[JCruse]

I got a whole mess of these maroon ones, they work fine but are not quite as durable as originals I think:



I can send a few if you'd like.

And a few of these because I found a few holding some panels.

 

[serenity]

Here is the waterproof version.
2mm aluminium with folded safety edge and 3mm closed cell backing foam, held on with m5 304 stainless button head screws and rivnuts.

Hijack over.

 

[musthave]

I made all my door panels out of stainless steel with sound deadening. What's nice is that I mount anything I want on the door no issues. And I don't care if they get wet.

 

[LS1FJ40]

With aluminum or stainless do you notice a noise difference?

 

[IanB]

I made all my door panels out of stainless steel with sound deadening. What's nice is that I mount anything I want on the door no issues. And I don't care if they get wet.

That would suck on a -30C morning, lol!