never say die, but know when to say uncle..

[Plymouthy Adams]

UNCLE..I have searched about the web and e-bay for a special tool used to cut the holes for the door panel clips...I have struck out..I know they must exist as the stock panel all have these neatly formed slots to install the clips...has anyone here knowledge of where to get one of these cutters...in the past I have always just drilled two holes and removed the material between for the slot..just hoping for a better method..

[oldmopar]

No good answer and this maybe be a stretch but the slots to me look like the type I have seen in wood working I think they have a bit to drill a square hole not sure of name maybe a mortisen bit ? and since you were drilling the holes maybe something like that would work

[55 Fargo]

UNCLE..I have searched about the web and e-bay for a special tool used to cut the holes for the door panel clips...I have struck out..I know they must exist as the stock panel all have these neatly formed slots to install the clips...has anyone here knowledge of where to get one of these cutters...in the past I have always just drilled two holes and removed the material between for the slot..just hoping for a better method..

Yup, employed my gasket hole punch kit, a harbourfright type.

I punched the 2 holes, tthat seemed to work in my case.

I may have also usedan exacto knife to finesse them a bit more to oem type slots, worked well in my case.......

[Plymouthy Adams]

well I asked here in case someone lucked upon ta cutter..My upholstery books I have here for guidance show nothing of the sort..I am however sure that the shop that did my 54 used a cutter of some sort..I may have to see if he can get me a cutter or at minimum cut my holes in the location I shall premark..I m certain that long ago I have seen this offered for sale..the quest continues..

[Richard Coney]

My auto upholsterer friend has two leather hole punches in differing sizes that he welded together. Basically they are short lengths of metal tubing with one end of each tube sharpened, much like when you sharpen a pencil. The inside diameter is untouched, but the outside wall of the tube is thinned to a sharp edge. When welded together they form a double circle or figure of eight shape. When he hammers the end of the tool the sharpened end cuts out a double circle in the mill board or hardboard (Masonite I believe you call it in the US), of the door panel. He then inserts the trip clip into the larger hole and clips it into the smaller one where it is held tight. When offering the new panel up to the door, line up the holes for the clips with the smaller hole to be punched. The tool should be pretty easy to replicate with some thickwalled tubing, a grinding wheel and a steady hand.

Hope this helps.

Regards,

Richard

[Big_John]

I just drill one hole, the diameter being the length of the slot.

[Oldguy48]

A 1/4" wide wood chisel works well, although a bit time consuming. Just place a piece of wood under the panel to back it up and have at it.

[Young Ed]

There you go Tim just weld 4 wood chisels together!

[Plymouthy Adams]

there are as many ways to get by as there are folks trying to get by..as for myself..I wanted to find the single one tool for the job..quick and easy..but of course, I am also aware I may be back to doing it a bit like the first wheel, knocking off a chip at a time..

[dezeldoc]

Take a piece of tube sharpen the end and flatten it out to an oval shape and instant hole cutter, as long as you are using that black heavy cardboard it should work fine.

[Young Ed]

The OEM holes are a rectangle I think thats the tricky part. Plenty of available ways to cut round holes. The square ones are a little bit harder.

[Uncle-Pekka]

What? - Did someone call me? ....

I would presume the original upholstery backing plates were made by an industrial plate cutter machine, thus there may not be any hand tool for this shape & purpose.

Do not recite my name in vain...

/Uncle-Pekka

[Richard Coney]

For a square cutting tool, take a suitable piece of square tubing, chamfer an edge on each side at one end so they are sharp and use as a punch. Line the punch up on the cardboard and hit the end whilst placed on a piece of scrap sofwood so you don't damage your bench or the kitchen table.

[Plymouthy Adams]

I like to use the thinner Masonite but again, its a bit tough compared to the black paperboard the shops use..so I may well be stuck with having to drill holes with a Forester bit and then use the Exacto saw to make the slot..the shop that did my 54 is off for the week of the 4th so getting through to ask them is fut for the moment..guess I will just cut the door panels and leave blank till they get back..besides..I like to put about two coats of polyurethane to seal these panels to some degree as it is...I have source lots of site with upholstery tools and have not seen anything offered. Not putting much faith into finding a cutter at this time..I appreciate everyone's input here..

[Richard Coney]

Why not simply use a sharp chisel? I confess I really like to find and use special tools for such jobs, but oftentimes forget that the simple methods are often the best.

[Plymouthy Adams]

I agree and falling back to simple tools will work, more time and steps involved..Masonite is a bit tougher to cut and to keep the edges of the panels sharp and non-distorted I feel Forrester bit work best..it is what I used for the Suburban's rear panels but these are all screw in panels from the factory..I have the door panels yet to cut along with all the panels for the bz cp these will add up to a number of holes to cut for certain..

[Young Ed]

Tim when I made my door panels for the p15 I just made a round hole and left it round. The OEM clips still slide into place just find. I think I made them all with a 3/8 spade bit but a punch of some sort would have worked better.

[Rusty O'Toole]

Forget the clips and use Velcro. It will hold your panel on tight, but allow you to remove it without damage any time you want to.

[Plymouthy Adams]

not nixing the idea, but I cannot imagine a need to remove the door panel often enough to use Velcro.....I will stick with convention..

[Suess]

Tim is there a way you can snap a shot of the hole. I do not have any to look at and I have tons of old upholstery tools. One of them looks like a leather punch that you insert different tips into.

[40P10touring sedan]

Greenlee makes square hole draw punches...drill a hole and insert the draw bolt and it pulls the two square dies together to cut a square...they come in different sizes.

It's been eons since I used one so don't quote the exact spelling of it...

[Richard Coney]

Backing up to the Velcro idea for a moment, how did you fix it to the door panel? Glue or staples of some sort? Whenever I've used wide strips of the stuff it doesn't stay stuck to the two surfaces unless sewed in place. If glued, what type did you use? Which side did you use on the door? The hooks or fuzz?Thanks. Richard

[Plymouthy Adams]

update..long story short..struck out on a one step tool....so used combination of Forrester bits and my jig saw..the weird looking shapes on the slender panels..outlined opening for the seat belt retractors..all but the kick panels are finalized blanks..next to put two coats of polyurethane to seal against moisture..

[randroid]

Tim,

Looking good with the holes but I question the "bench" you used to make them. Hope you aren't planning too many competitive games on it.

-Randy

[Plymouthy Adams]

trust me Randy..no work done on that table..just storing them under the table for now...figured to take the photos there only..all edges have been sanded on all panels..wife's sister and kids visited couple weeks back..that game room sure got a work out..the pin ball machine was going full out..