How to make door panels
 

I told some friends on the site about doing door panels so here it goes. This is how I do interior door panels. There are many ways to build them, but this is how I do it. There is no sewing, all glued and stapled together. I learned most of this from the DVD from Sid Chavers.

All of these pics were taken today, but I had started some of the work last week at Ed's place, where his car is kept. Can't use my shop now, it's full already, so I did most of the primary sizing of panels at Ed's and then brought back to my shop.

Re: How to make door panels
 

Here was the current door panel on Ed's 1947 F@rd coupe. Not bad, but it wasn't what he wanted. It didn't show enough of the shape he wanted, to heavy with the foam, etc., and had ugly screws holding the panel to door (see pic 1).

But the main problemwas that the door panel and arm rest were so wide that they hit his seat (see pic 2). You would have to SLAM both doors to close them. He has already broken two door windows on the passenger side. So I'm going to slim it up and make a new panel.

Re: How to make door panels
 

I use 1/8" lauan, some call in sub floor, or you can use 1/8" wood wallpanels. Lauan will bow going with the grain. So if your door has a bow, left to right, or top to bottom, make sure to put the grain that way. I cut the panel close to the size of the door. I then place it on the door and use to small metal screws to hold the panel in place. Trace the outside of the door to the back of the panel. Remove and cut panel to shape. Reinstall the panel with the two screws and check for alignment. This door already had holes from the old panel, so I used a shape awl to transfer the holes to the panel. I then removed panel and used a hole punch to make the holes and installed the door clips. I'll tell size of punch and show clips tomorrow. First pic is how the panel looks and the second shows how panel can bow.

Re: How to make door panels
 

Now you need to trace the first panel to another sheet of lauan to make a second panel the same size as the first, this pic shows the ruff size. I almost forgot make sure after you cut your lauan, you sand all edges with 80 grit sandpaper, to make it smooth and get rid of the splinters.

Re: How to make door panels
 

Ed and I had come up with a design at his shop, that was lightly drawn on masking paper, I brought that home and refined it, the used a marker to show shape (see first pic). I then cut that out with a razor blade (see pic 2). I used that template on the second panel to mark with pencil for where panel will be installed.

Re: How to make door panels
 

I then take the inner template and mark up another piece of lauan (pieces from sheet for first panel), to make a hard template (see pic 1). When cutting out an inside opening I usea saber saw. I drill a couple hoes to start and cut out the design. Go slow and follow the lines and it should work fine. This piece is what came out, but can not be used (see pic 2). After hole is cut I use that piece to make a hard template for the arm rest (see pic 3).

Re: How to make door panels
 

Now I use that hard template on the second panel where I had the pencil line from the masking paper. I use a marker to outline and then I cut out the panel (again using the saber saw) see pic 1. Here the panel is removed. see pic 2

Re: How to make door panels
 

Here is the second panel with all cut outs, laying on top of first panel for the drivers side (see pic 1). Here is the passenger side taped in place and ready to be marked and cut out (see pic 2).

Re: How to make door panels
 

That's where I left off at tonight, will see how things go tomorrow and hope to have another update. Hope this made sense, on how I'm doing this, if not, ask questions and I will try to explain better...Jim

Re: How to make door panels
 

Great tutorial Jim. Thank you for sharing the how to.

Re: How to make door panels
 

Yes, thanks for the tips!

Re: How to make door panels
 

Thanks guys, appreciate you checking out the thread..Jim

Re: How to make door panels
 

Thanks oldman3. Its always good to learn something like this. Enjoying the process of what you are doing. Will watch till the end.

Earl

Re: How to make door panels
 

Thanks Earl, could not work on it yesterday, 6" snow and other health issues, but will be back on it today, with an update...Jim

Re: How to make door panels
 

Great to see this kind of thread. Thanks for sharing Jim.

LIZ - This is the kind of thread that I would like to see for the Interior Forum I have mentioned....

Sorry to hi-jack this Jim, but fits with something I have asked for here:
http://67-72chevytrucks.com/vboard/s...d.php?t=660687

Re: How to make door panels
 

Im in to the finish. I am a carpenter but doing something like this is out of the norm for me.

Re: How to make door panels
 

Thanks Aggie 91. I posted on your thread and also on the link Liz showed, so I hope it shows up that I would love to have an Interior forum. Karl you didn't hi-jack, it made me aware of what you were trying to do, which is great...Jim

Re: How to make door panels
 

Thanks, will be giving up update here real soon...Jim

Re: How to make door panels
 

Well, things were really messed up yesterday. 6" of snow, health problems, so I'm late on the update. I mentioned I would show the punch and clips I use. So I'm going to start there and then continue with the panels.

First pic is the punch I use, it is a 1/4" hollow punch. The clip on the left is the clip I'm currently using Auveco #11406. The clip on the right is better, but it is getting harder to find, and Auveco no longer shows a part number.

Second pic shows how the punch makes a clean hole, or you could use a 1/4" drill bit.

Third pic shows the clip installed.

Re: How to make door panels
 

Here in the first pic I've put a scrap piece behind the top scrap piece

Second pic shows the gap between the two panels. What I do is mark thru the first panel clip area on to second panel.

Third pic, I then take a cut off wheel (using the edge) and remove approx. 1 layer of lauan to create a little dip in the panel for the head of the clip to lay. 99% of the time when removing a layer it will change color.

Pic 4 now shows how flat the two panel lay.

I'm showing all this now, because as the two panels go together this is how it will look.

Re: How to make door panels
 

Okay now back to the door panels. This first pic shows me cutting out the design on the pass. panel, with the saber saw.

In pic 2 you see the first panel with clips in place.

In pic 3 is a larger view of pass panel, ready to insall the second panel. We will return to this panel later.

Re: How to make door panels
 

First pic is the contact glue that will be used to put the two panels together. You can also buy the same glue at the lumber or hardware yards, but it's in a red and black container.

Pic 2 shows how it looks.

Pic 3 shows the new spray gun I'm using now. I used to use an old siphon type spray gun, but this new one works better and always sprays the same, never have to adjust the pattern.

Re: How to make door panels
 

While I'm showing tools for this build, Pic 1 is my air stapler for interior work.

Pic 2 is the staples I'm using now 1/4".

Pic 3 Back to the panel, it doesn't look like it, but I have sprayed a light coat of glue on this panel, and also on the second panel (no pic).

Re: How to make door panels
 

In the first part of this post I stated that you had to make a exact copy of this first (base) panel, for the second panel. One of the reasons is the second (design) panel has to cover all the clips, so there is no bump. Another is now your panel is 1/4" thick and feels better. When your ready to glue the two together it is best to check two or three times on how you want to attempt this. Cause once they are stuck together it won't come apart. Two people makes in better, but you can do it by yourself, just be careful.

In this pic I've glued the second (design) panel to the first (base) panel, and I've stapled the panel down in several spots. (that's just something I do)

Re: How to make door panels
 

Here are the pass. and drivers panels glued and stapled together. They are now ready for foam and leather. With the two different wood colors (based and design), you can see ow the design of the panels will look. If all goes well, I hope to cover them in foam and leather tomorrow, till next update...Jim