Door panels

[Oldguy48]

Does anyone have any tips or advice for fabricating new door panels? I just started making new ones for my P15. Purchased the proper sheet material from the upholstery shop and started to lay it out. The original ones were badly deteriorated, so I don't think I can use them as a pattern. And my upholstery guy warned me that more than likely, the door panels would not be mirror images from one side to another. I didn't think it would be too tough to do, but so far I'm not too confident they will turn out OK. I've got all the tools I figured I would need...square, measuring tape, trammel points, etc., and I've tried my best to make accurate measurements, but so far I'm not pleased with my work. I'm certainly no engineer, but I can usually do fairly well with layout work. I'm hoping I can cut out the rough overall shape, place it on the door and trace around it, and then locate the holes for the retaining clips, etc. Rather than rely on my own meager skills, I decided to toss the question out to the experts. So if anyone has any suggestions to make this job go smoother, I'm eager to learn. And yes...I did search the forum prior to posting this, but didn't find anything.

[Young Ed]

Here's my thread on making them. Use your old ones as a pattern and if you think they are deteriorated cut wide and then install and trim to fit. Other tip I can give you is if you are using the OEM clips there are 2 sizes and the holes for the clip are adjacent to the hole in the door. The longer clips go along the bottom to go through the rubber strip and still make it into the door.

http://www430.pair.com/p15d24/mopar_forum/showthread.php?t=22019

[1950 Special Deluxe]

I was able to use my existing cardboard panels as a template.

As per previous threads, I used the plastic signboard.

Mine turned out OK(?)

[Rusty O'Toole]

Notice that on all cars since the fifties the door is sealed by a vapor barrier of clear plastic, with caulking around the edges. This is important to stop the door panel from warping. Doors are always getting wet inside because the window rubbers are never water tight. Keep the drain holes open too.

Forget the OEM clips, use Velcro to hold it on. Works perfect and makes it easy to remove the panel if you need to do repairs to the window mechanism or door latch.

If your old panel is warped, torn and wrecked why not make a pattern of cardboard, if it is no good throw it away and start again. When you have the right shape trace it on your new panel.

For a smoother more luxurious look use "landau padding". This is thin foam rubber 1/4" thick. Glue it on the panel then glue on the cloth.

There is a method used by upholsterers to fit the cloth or padding. Lay it on the panel dry and move it around and smooth it out perfect. Then carefully fold one half back over the other half. Glue the first half. Then fold the other half over the first half and do the same.

[Oldguy48]

Thank you for the replies. They are all helpful. And it never occurred to me to use Velcro...brilliant idea, because laying out the holes for the clips was one of the things causing me fits. And I wasn't aware that there were two different length metal clips in the original panels. When I purchased the car, the door panels had already been stripped of the original material, and replaced with a cloth that resembled black & white cowhide. I knew you guys would be able to help me out. Thank you so much for your assistance.

[Young Ed]

I considered the velcro idea too but didn't use it because I thought it would cause too big of a gap between the panel and the door.

[Robert Horne]

On my 38 I used salvaged the headliner out of a Dodge Van, for material, that was thin panel board with a thin foam covering. I used 38 headliner material to cover the Dodge panel boards after cutting to fit.

My original 38 door panels are 3 layers of black roofing material glued together. Old as they are, they are in fair shape.

[Rusty O'Toole]

I considered the velcro idea too but didn't use it because I thought it would cause too big of a gap between the panel and the door.

When you wrap the material around the panel it makes a raised edge especially if you use landau padding. The Velcro goes inside that and when the 2 halves are pressed together it is quite thin.

[Young Ed]

When you wrap the material around the panel it makes a raised edge especially if you use landau padding. The Velcro goes inside that and when the 2 halves are pressed together it is quite thin.

I guess I can see that working. I just didn't imagine it that way when I made mine. I still have a ton of velcro from another project so maybe on my next vehicle I'll try it. How did you attach one side to the door? weatherstrip adhesive? Screws/clips?

Edited January 26, 2012 by Young Ed

[OldDad67]

I was able to use my existing cardboard panels as a template.

As per previous threads, I used the plastic signboard.

Mine turned out OK(?)

Those really turned out nice, I'm inspired. That upholstery intimidates me.

:eek:

[Rodney Bullock]

My Plymouth door panels were made out of a card board that does not warp. It was renforced with water proof material from the inside. The material that covers it is a very thick tweed. I remember when they made these boards. They traced the originals. There was a special tool that they used for the holes and the clips fit perfectly. I lay a peice of plastic between the board and the door. The guy that did the work on my Plymouth really took pride in his work. The car is very tight inside. The headliner was so tight not a single wrinkle.

The Studebaker was not so ucky as the boards were made out of the same material as usual. they have warped. The guy and I steamed them and got them back to shape because there was no material to match what I had in there and no money to redo the whole thing over. So what ever you do protect it from wetness, the interior of these cars is expensive.

[old rat 49]

I like to use 4 mil plastic, spray glued to door as a weather liner between door and interior panel like the new cars use. I also noticed on the rear side windows that Plymouth had a tar paper deflector hanging inside the body that made water drip away from the interior panels. Maybe someone has a pic of that to clarify. Painted my dash yesterday and as soon as that is back in am starting on my interior also. Thinking about using the velcro method too.

[Robert Horne]

I used thin black roofing felt to copy my original door panels.

I used the same felt as a water vapor before installing the door panels,

I made from a Dodge Van.