Re: How to make door panels
 

Very clear and easy to follow Jim. I could print this out, take it to the shop and make some door panels...maybe. Probably make some scrap panels first as is part of learning process.
How do you determine where to put the clips? Or how do you transfer the clip location to the door accurately? Thank you!

This should be a sticky in the interior forum. :)

Re: How to make door panels
 

Thanks Doug,
Believe me I've made plenty of scrap panels. This job the door already had holes I just lined up the awl and pushed thru the panel. If your starting from scratch, put the panel on the door and drill holes thru the panel into the door. Depending on size of door about 4 holes on the sides and 5 along the bottom....Jim

Re: How to make door panels
 

Subbed!

Re: How to make door panels
 

Well time for todays update. Not as much done as I wanted, but still progress.

First pic is the pass. panel that will be covered today.

Second pic is the 1/8" closed cell foam (also called sculpting foam, or landau top foam). I cut out some of the foam to it won't stick in that area.

Third pic you can see the glue has been sprayed on the foam and the panel.

Re: How to make door panels
 

First pic, I thought I would show this glue for those that don't have or don't want to buy the equipment I'm using. This stuff works great and can be picked up at your local auto paint supply.

Second pic, here I'm installing the foam. I start at the top and work my way down, moving left to right to keep it smooth.

Third pic, here the foam is in place. I use a bondo spreader to help lay the foam down.

Re: How to make door panels
 

Mark needed to spray some primer, so I left the shop for a couple hours.
First pic shows the foam in place and excess foam has been removed. I use a razor blade to cut the foam.

I messed up and didn't take any pics, but after the foam is on, you are ready to cover with material. I roll out the material, place the panel on the material. I leave about 1-1/2" extra around the panel, mark it and then cut out the material. After material is cut to size I place the panel right side up and material right side up, to check and make sure everything is OK. I then pull the material over itself about half way down the panel, so the back side is up. I then spray glue on the top half of panel and the back side half of the material. Let this tack up, then I use the spreader and start up the under side of the material to attach to the foam. Once that's down you can go back to the design area, use the spreader to puch the material down and along the design edge.

Second pic shows this done, and I also put in a few staples along the edge.

Now do the same thing to the second half of material and foam to finish the bottom of panel. You would also use the spreader to push the material down for the two design lines.

Thrid pic shows this done.

Forth pic shows the entire panel and material.

If what I explained isn't clear, let me now and on the second panel, I will take more pics.

Re: How to make door panels
 

First pic, I also forgot to mention that I use 4 or 5 pieces of 2"X2" blocks under the panel to keep the clips from touching the work area, so you can work on a smooth surface.

Second pic, I've turned the panel over and glued the material to the back side.

Thrid pic, I've stapled down the material to the panel.

Forth pic, For those that don't have an air stapler, this hand unit works fine and uses the same staples, this one is made by Craftsman.

Re: How to make door panels
 

First pic, I've sprayed glue for attaching material to back side and will show to do the corner.

Second pic, shows everything glued and stapled in place. In the first pic you notice the cut material. I first staple the piece to the left, leaving just the small corner material. I will work this around the corner, as smooth as I can, and will the least amount of material overlap.

Third pic, is a close up, but a bad pic, sorry.

Forth pic, after everything is stapled down, I go back with a razor blade and trim the excess material away.

Still have more work on this panel, but my back was getting to me, so I quit for today. Will see how things go tomorrow...Jim

Re: How to make door panels
 

The back side is white... is that a sealer? Will you be adding an arm rest to these or something to grab and close the doors? I notice there is no handle holes or holes for window cranks.... is this car without window cranks or door latch handles?

Re: How to make door panels
 

Owner of car bought wood paneling, that's why it's white on the back side, but works fine. Yes, I will be building a custom arm rest, will show in detail later. This car has power door locks and power windows with the controls in his center console, so no holes. Thanks for checking out the build...Jim

Re: How to make door panels
 

Ok, curious to see the arm rest and how you do that. Hope the back feels better... I know all about the bad back thing. No fun at all.

Re: How to make door panels
 

Great update Jim. When do you cut the material away for the shaped opening? Believe it has to be during a test fitting. Take care of you back!

Re: How to make door panels
 

Thank you...Jim

Re: How to make door panels
 

Doug, you are correct. After I've checked it a couple times, I mark inside the design shape, and cut out the material. This allows the material to move a little easier when gluing to the shape. I'm watching the back and thanks....Jim

Re: How to make door panels
 

When I left off yesterday, I had one side to finish gluing and stapling the edge in place on the pass. door panel.

First pic shows four notches that I cut in the board, when I put the two top pieces on, this will be used.
Second pic shows the top side with notches, sorry bad pic.
Third pic shows everything glued and stapled in place.
Fourth pic show the side view with two pieces of 1/8" lauan, 1 piece of 1/8" foam and then the material.

Re: How to make door panels
 

First pic, shows how I trimmed off the excess material from the top of panel, using a razor blade. This lip will fit under the window garnish molding.
Second pic, is how the panel looks.
Third pic, shows me trimming more material, where the design panel will go. Don't want to make this bulky.
Forth pic, show the thickness of the panel, it's now approx. 3/8" thick.

Re: How to make door panels
 

First pic, here I've placed the design panel in the opening with scrape pieces of material to check for gap in the opening. I want the panel to lay flat as possible. I need to remove just a small amount from the edge of the panel, so it will lay flat.
Second pic, I use a sanding block with 80 grit paper and sand the outside edge of design panel till it fits the way I want.
Third pic, I do the same thing for the two other panels.

Re: How to make door panels
 

First pic, now I'm moving to the drivers panel. Here I've laid the panel on top of material and left a 1-1/2" extra, and now ready to cut material.
Second pic, with the extra material on the side of material I made up 4 strips for the small design strips for later.
Third pic, on this panel, when I glued the base and second panel together it was mis-aligned. Top panel was now short, so I mixed up some filler (bondo) and applied where there was a gap to even out the panel.
Forth pic, all sanded and smooth. No one will no the difference, once foam and material are over them. I'm showing this so if this happens to you, there is always a way to repair.

Re: How to make door panels
 

Thanks Jim, I really like the way you take your time to teach us old dogs some New Tricks

Re: How to make door panels
 

First pic, here I've sprayed glue on the drivers panel and the foam for the top half. After in tacks up I used the spreader to lay in place.
Second pic, same thing now done to the bottom half.
Thrid pic, Foam blued in place and design cut out with razor blade.
Forth pic, Here I've laid out the design panel for cutting foam, which will be applied later.

That's it for today, hope to get more done tomorrow, till then...Jim

Re: How to make door panels
 

Thanks Jim for sharing this. I have always wanted to do my own panels but really never knew how. Gonna have to give this a try someday!

Re: How to make door panels
 

Karl, you welcome. Hope others are enjoying it...Jim

Re: How to make door panels
 

Update time again.

First pic, here I've cut out the foam for the panels and applied glue.
second pic, glued panel to the foam (pass. side).
Third pic, sprayed glue for the drivers side.
Forth pic, all glued together and excess foam trimmed with razor blade.
Fifth pic, here I've laid out the panels on the materila for cutting.

Re: How to make door panels
 

First pic, here I'm changing from 1/4" staples to the 1/8" staples, which will be used shortly.
Second pic, glue applied to panel and material, wait to tack up.
Third pic, all glued down, the black lines are were I'm going to cut for the corners. Only cut down so it's about 1/2" from panel.
Forth pic, same here.
Firth pic, here I've added relief cuts for the corner.

Re: How to make door panels
 

First pic, relief cut at this end also.
Second pic, here I've sprayed glue to the edge of panel and material.
Third pic, I've rolled over the material onto the panel.
Forth pic, here's where the 1/8" staples are used. Since it is only the panel and foam, anything longer would stick through. I've stapled the material to the panel.
Fifth pic, showing the other end.