DIY door panels

[Young Ed]

After my recent success with the clock I'm onto another project. Dug my old door panels out of the garage. They are mostly intact certainly good enough for a pattern. I did a search on old threads and seems like a few different options were used for material. The original cardboard type stuff, ABS plastic, or various woods. Any more options or a consensus on whats better? I'm currently leaning towards plastic but that will be somewhat dictated by cost and availability. After I get a good start on the actual panel I'll followup with fabric questions

[gnordlie]

I just finished my front and back panels and I used 1/8" fiberboard. It works, but I'd go right to an upholsterer(sp) and get door panel material. What I used was hard to get staples in and I wonder if the window and door handle escuthcheons with the sharp pointed edges will stick in that hardboard. My 48 original front panels had 3 sewn strips and that is harder to do with the hardboard. I used 1/4" foam backing. I found the hardest part is getting all the fasteners in the right spot.

[BobT-47P15]

I think the door panel cardboard used by auto trim shops is fairly water

proof due to some type of treating. It is more flexible and pliable than

other tougher stuff. I currently have masonite for door panels I made

myself. Those escutcheons for handles certainly won't stick into them.

And, I haven't even bothered to try and put the stainless trim strip back on.

For inside the trunk and kick panels, I used heavy cardboard type stuff

from Hobby Lobby. (There is a guy on ebay selling pre-made kick panels

for a P15.)

So, suit yourself.......but I tend to favor the upholstry shop sort of

cardboard. I hope to get my interior re-done this year, and it will

be by a shop.

This is one of my original door panels......just a bit worse for wear.

Being a convert, they were either leather or leatherette.

They had been re-covered once with some oil cloth type material,

which I pulled off.

Were the cardboard type panel.

Pretty "plain jane" for now......with the $6.95 per yard vinyl from the

fabric store.

[Young Ed]

Bob my original ones aren't quite that bad but close. I think the last time we tried to buy the OEM type stuff they wouldn't sell to the public. We had to have our neighbor who does interiors buy it for us. The ABS route seems fairly expensive. I once thought about using the sheets that are plastic on each side with foam in the middle. Anyone ever try that?

[Hounddog]

I acually used the fiberboard I got a lowes for 11 dollars. The sheet was big enough to do all 4 door panels and I just got some black vinyl for about 25 dollars at the fabric shop used the original trim(although I like the look without the handles and put the trim on backwards) for the trim i used a small punch and punched holes in it and just poked through the fabric, it was pretty simple used very small tacks and adhesive spray stretched it out and pressed it on. Its not the best looking but its a lot better than it was. all in all the 4 doors cost me about 40 dollars and some time. I bet if you used thin foam inside it would look good also. Here is a couple pictures I still need to add the rubber on the bottom and add the screws up the side but its ok for now. All in all this was me and my g/f first door panel ever.

[randroid]

Hounddog,

On which one of the doors is the trim up-side down? Not trying to be critical; it looks good.

-Randy

[Hounddog]

Well in the first picture you can see how the small flat piece is near the inner door and when we redid it its toward the outer doors. I think it looks really good for the first time and next we will tackle the headliner and carpet, seats will have to be done dont know how to do that at all.

[Allan Faust]

I used coroplast to make some kick panels.... it worked quite good.... will probably use it for all panels.... only about $20 for a 4x8 sheet... lightweight, rigid, waterproof, works easily.... used a 3M glue to glue the tweed to the panel.

Allan

[1948Matt]

I used coroplast to make some kick panels.... it worked quite good.... will probably use it for all panels.... only about $20 for a 4x8 sheet... lightweight, rigid, waterproof, works easily.... used a 3M glue to glue the tweed to the panel.

Allan

That looks great! Where do you get a sheet of coroplast?

[Allan Faust]

Any home building supply.... its a sheet that normally would be used to make signs.... its hollow plastic, ie tubes run the length of the sheet... about 1/4 inch thick....

Allan

[Allan Faust]

This is what it looks like, you can get it in different colors as well, but covered, it doesn't matter.

Allan

[old woolie]

I used coragated [sp?] plastic signs like you see at fast food restaurants and gas stations,got them free. Cut to fit using old ones as patterns then cut cloth 3 to 4 inches wider all around,laid cloth on table,sprayed aerosol glue on panel,laid it on cloth,flipped it over,smoothed the cloth out quickly then trimmed,folded and glued the excess to the back side.

[Jerry Roberts]

I like the idea of using waterproof materials , there can be a lot of rainwater flowing through the doors . On my more modern truck there is a thin film of plastic stuck over the access openings before the door panel goes on .

[Allan Faust]

I used coragated [sp?] plastic signs like you see at fast food restaurants and gas stations,got them free. Cut to fit using old ones as patterns then cut cloth 3 to 4 inches wider all around,laid cloth on table,sprayed aerosol glue on panel,laid it on cloth,flipped it over,smoothed the cloth out quickly then trimmed,folded and glued the excess to the back side.

That is coroplast....

[old woolie]

That is coroplast....

I realize that now,I didn't know the proper name. You posted between the time I read this thread and when I posted. Thanks for the info.

[Captain Neon]

That looks great! Where do you get a sheet of coroplast?

Just wait until summer, and politicians will be able to supply you with as much corroplast as you want just free for the pickin's. Wait until after Election Day and the losers will think you are doing a good deed picking their signs up for them.

[Captain Neon]

I acually used the fiberboard I got a lowes for 11 dollars. The sheet was big enough to do all 4 door panels and I just got some black vinyl for about 25 dollars at the fabric shop used the original trim(although I like the look without the handles and put the trim on backwards) for the trim i used a small punch and punched holes in it and just poked through the fabric, it was pretty simple used very small tacks and adhesive spray stretched it out and pressed it on. Its not the best looking but its a lot better than it was. all in all the 4 doors cost me about 40 dollars and some time. I bet if you used thin foam inside it would look good also. Here is a couple pictures I still need to add the rubber on the bottom and add the screws up the side but its ok for now. All in all this was me and my g/f first door panel ever.

Micah, it looks to me that a PO put the trim on wrong. I think you have it the way a Special Deluxe is supposed to be. You wouldn't happen to have any spare interior door trim would ya?

[LAKOTA169]

A local guy here uses very thin aluminium. I was going to have him do my doors, but I lost his number. doesn't have a shop. I did see one 1940 Plymouth (hot rod) that he did the whole interior on, and he does good work. Don't know how he mounts the cloth to the panes. I know he uses the little "Christmas tree" looking fasteners to mount the panels to the door.

[Young Ed]

Micah, it looks to me that a PO put the trim on wrong. I think you have it the way a Special Deluxe is supposed to be. You wouldn't happen to have any spare interior door trim would ya?

Ben not sure I've got an entire set but the door panels from the 4dr I parted out are still around. Would be a good start at least.

[Hounddog]

Im not sure if its backwards but it seems like all the cars i see have the trim another way. I like how mine is and I dont intend to put the handles back on so I dont need to change the trim around. My buddy at work says he knows someone that can redo my seats so maybe I can get the interior done eventually.

[Young Ed]

Besides "borrowing" signs from my neighbors yards what's another good source for the coroplast?

[Hounddog]

I have seen it really cheap around 5 bucks a sheet at hobby lobby... not sure if you have one around you?

[Young Ed]

Not that chain specifically but there is a huge hobby shop called hub hobby here. I used to spend 100s in there on 10th scale RC cars........

[Hounddog]

One of my buddys is into the r/c cars he has spent around 3000 dollars on one car that he races around the track. I told him for that much he could have bought a real car and have something that would last.. I guess to each his own. I couldn't see spending that much on a r/c car just to break it everyday... of course I do the same to the plymouth so I guess I dont have room to talk.

[Young Ed]

I haven't played with mine in quite a while but I bet I've got that much into the 4-5 cars I have. I kinda got out of them right when I got my first old car.