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casor 08-18-2012 10:16 AM

911 Door Pocket Repair
My 78 SC has those miserable cardboard door pockets. When taking the car apart for a resto a few yrs ago (!), I saw one was cracked and the orig's are either not available or really exp. I did not want to go the option of the glass panels - too exp, not orig and a fair amt of work to install correctly.

Since I was redoing the carpets on my car, the door pocket carpets had to come off and did so rather easily with a little heat. I could then see the extent of the crack, which was about 3-4 in long.

To repair, I cleaned off the carpet glue residue with lacquer thinner and then sanded the area pretty good with 150 paper. Don't overdo it but get it roughed up. The crack realigned itself with a little pressure - it was helpful to elevate the center of the pocket under the crack about 1/4" to get it to line up and go back together. I then tacked the crack with a few drops of thin cyanoacrylate (CyA) - model airplane glue - to the point where the crack would not reopen.

To reinforce, I used 2oz glass cloth over the area leaving about a good 1/2" on either side of the crack. To secure this, I switched to "gap filling" CyA over the cloth and crack together, pressing it down with a finger in a plastic bag to smooth it out and to work the glue into the porous, roughed up surface. The repair is very strong and thin enough that you won't see it under the carpet. The inside of the pocket will be touched up with some black spray and maybe some more flocking.

CyA can also be used to fix delaminations along the edges of the pocket with a couple of clamps, some waxed paper and thin plywood to keep everything straight......

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