Making door panels

[tonyfromjersey]

I am thinking of making some door panels. I know a guy who can do the vinyl work. I would love some suggestions and/or tips for this. One big question I have is what to do about the upper (curved) portion. Can I use what I have and somehow attach some type of wood to it for the bottom section, or do you make it in one piece?

I haven't bothered to rip the old ones off yet to take a look. I'd like to be ready to build (materials in hand) before I do this, I'm trying to avoid downtime now that the weather is good. But the old ones are gross and I want to get rid of them (and the inoperative speakers in the doors as well).

[pope]

Tony, all your questions will be answered once you dismantle the door panels.The upper round portion is metal and will be reused. The lower portion is fibreboard and you can remake this. The two pieces are held together with spread tabs that are attached to the chrome strip that runs across the upper door. Save the old vinyl for templates.

Take photos as you dismantle

Good Luck

[tonyfromjersey]

Pope,

Thanks. I will get after it next week. If I can do my own canvas top, how hard could this be? I learned the picture thing years ago, digital cameras are a boon to the do-it-yourself types like us.

My neighbors think I'm some sort of genius because I can fix all sorts of stuff and am not afraid to try. Also, I own tools! And I mow my own lawn! They really think I'm nuts working on my own car, too.

[azygoustoyou]

Hi Tony,
I'm doing the same. I have mine apart. It would be very easy to make the panels. If I didn't have so much going on, mine would be done. I already purchased the materials to do them. Except for the board. LOL You'll need some 1/2" backing foam for the material (vinyl) you'll use. You can wrap the vinyl over the front to the back and use staples to hold it on. I remember there is a rivet on the top curved piece where the rubber or felt is for the window. If you want a more decorative design on the panel, you could top stitch the vinyl to the foam to give the look of the original panels. If you do that, you'll need some adhesive to hold the foam in place with the vinyl when you stitch it. This is going to be a winter job for me. I'm doing all the interior including the seats. That's when I'm going to fabricate a custom dash also.

[pope]

Tony, I would not try to produce a top, because the top on your car is shrunk over time and will make an inaccurate template. Also the tops are rather inexpensive and usually heat sealed on the threads to make them waterproof. The canvas tops are two pieces of canvas with a layer of butyl rubber sandwiched in between. Save your time and money and buy a top.


Brady, If you use 1/2" foam, you will have an impossible time closing the door, rolling up the window using the knob, and pulling the door lever to open the door. 1/8" no more, 1/4" if you want to live dangerously. Originally the doors had a micro slim green matting to back up the vinyl. There are 5 pop rivets that hold the window felt on, and three spread tabs that hold the upper black vinyl to the lower half. The thicker you make the lower portion, the harder it will be to attach the black curved area, because it sits on top of the lower portion to get attacked.
My advice... think Jenny Craig and go slim!

Good luck guys,

[mbouse]

i strongly encourage you guys to do this on your own. go to the upholsterer and buy the supplies, but take the time to enjoy this restoration project yourself.

i have a kazillion pictures from when i did mine last year... was meaning to write a how to. but, like pope said.. take pictures as you slowly disassemble. you will find this a very enjoyable D.I.Y. project.

tell your upholsterer what you are doing, and he will gladly sell you the supplies you need. you may have to get your own 3m spray can of contact adhesive; but the upholsterer will have the backer board and the vinyl and the padding.

i figured i saved a miniature fortune considering what they want at the catalogue suppliers for new panels. plus, i got some enjoyment out of the process by doing it myself.

[tonyfromjersey]

Pope,

I bought a top, my neighbors thought it was magic that I installed it myself. I used the instructions emailed to me by Mike and it was easy. I'm glad I asked this on the forum, I think I will pull the old ones tomorrow and go get materials, etc. This will be a nice little cleanup that I've been wanting to do.

I agree Mike, considering what is involved I think 400 bucks is absurd for these panels. I am going to start tomorrow, as long as I don't get called out to fly.

[pope]

Tony, I thought you were asking if you could make your own top. Now I realize you were asking if you could install you top. Install away.

[mdrburchette]

When I decided to make my door panels, I first bought the board from Lowe's and found it was way too heavy and would not contour to the door itself. My interior trim guy gave me a piece of backing board that was like a plastic coated foamboard. It was thin and very easy to cut out and bend, and the best part about it is it won't rot if it gets wet:



If anyone needs any of those eyelet rings for the door handle, let me know. I had to buy them in bulk.

[mbouse]

those grommets for the door handle spindle are a specially large size, not commonly found at your every day hardware store. take advantage of Denise's offer if you are planning on doing your own panels.

[pope]

Nice clean doors Denise.

[azygoustoyou]

Nice looking panel Denise. Do you still have your car on the rotisserie? Got any new pics?
Take pics Tony. Can't wait to see what you come up with. I have to wait till Winter.
Thanks for the input everyone. Those type of tid-bits really help. I don't want to do things twice.

[NJFIAT1981]

Hi Tony,
Take lots of pictures of the door panels when you pull them off. I currently have two seats and two ugly door panels as an interior. I have to replace everything. Might have to ask some questions. See you Sunday

[OrangeCrush]

I'm doing my own door panels along with the rest of the interior restoration on a 75 Spider and concur that the advice from others about going the slow and steady pace along with pics as you disassemble is sound advice. I purchased "project" board as LOWES calls it that matched perfect in thickness and even has a smooth side and a textured side just like the originals. Leather was going to be the re-cover material however I have yet to find what I'm looking for in my price range due to the fact that what I have found in that price range is this Graphite Blk which looks dull or like flat blk so I'm back on regular black shiny vinyl. LOWES also had a door weather stripping that I had to customize to replicate the originals that's just like the brush type molding that allows the window to guild near the steel contoured portion of door panel. The only problem I'm having is finding the rubber donut that goes around the window handle that's sticks to the door itself that keeps out the elements it looks like. I have one intact on one door but the other has lived a long full life and has now become ash's to ash's and dust to dust. An ebay auction served me well with a recently won set of mint condition door handle release's and that was sweet considering the price of those elsewhere and the fact I had none on one side and a broken one that looks like it came off of some 70's model Vega or something. Save everything as someone mentioned as patterns/templets.

Hey Denise! Were you able to replicate the piping along the edge of the panels too? I don't see it in your photo. I'm either going to go without or send old crap to Mom and have her sew me up some stuff on her Husqvarna.

Good luck man and happy upholstering!

[mdrburchette]

Yes. the piping doesn't show up in the pic, but I do have it.
The rubber donut you're talking about, isn't it more like a clay that was gobbed around the handle?