$245 for new door panels? Ha!

johnnyo200 · 12-31-2002, 07:59 AM

Just wanted to show my little weekend project.

The door panels on my car looked like hell, but I just couldn't justify spending up to $245 on new ones. I had some lexan lying around and I set off. I pulled all the staples out of the vinyl skin, used the old warped press board panel for a template, cut a new panel out of the lexan, got some new foam and glued that on with spray adhesive, (as well as a few strips of foam on the door side like original to stop vibration/insulation) and hot glued the cleaned-up vinyl skin to the new panel. Topped it off with new door clips, and there you go.

Let's see, for 2 door panels:
$3.50 -Clips (Don't even bother buying generic/cheap ones. They won't fit.
$4.00 -New Foam
$30.00 -Lexan (Approximation, could use cheaper plexi, but it has a tendancy to crack and it won't stop bullets

Grand total:
$37.50

I wanted the original panels, but now I might just go ahead and make another set of the RS panels too.

VincentVega · 12-31-2002, 08:01 AM

Nice work!

johnnyo200 · 12-31-2002, 08:24 AM

Thanks Chris. Does anyone have pict.s of the RS panels on their car and/or has anyone priced hardware for them? I would definitly want to use original P-parts for that. I just wasn't sure if I wanted to lose the pockets.

MotoSook · 12-31-2002, 08:54 AM

WOW! Here I just spent 190 on Ebay for the RSA panel kit? I suppose I need to learn to be more resourseful. Do a search on this BBS and you'll see some examples. I like the pleated look of the OEM panels, but they couldn't make me one. I might have to play with my old panels to get the look I want. I also thought the door might look good with just the arm rest w/o the door pocket, but that might look funny...I'll have to be creative.

Great Job!

keitho64 · keitho64's Garage

Here is a shot of the homemade RS door panels on mine. I think I have about $80-90 in them. I used porsche straps (the most expensive part), MGB pull handles and home made door panels.

toyboy · 12-31-2002, 09:16 AM

Keitho64,
Could you please lend me the part number for the Porsche RS door strap that you have used in your construction?. Thanks for your help. Best, andrew

RickM · RickM's Garage

Johnny,
The panel redo looks really professional. How thick was the plexiglass you used? Same thickness as the original panel? The only drawback I can see is the possible weight gain by use of the plexi. I'll have to keep this project in mind if I ever need to rebuild my door panels.
Rick

johnnyo200 · 12-31-2002, 11:02 AM

After seeing how the panels are made from the inside out, it doesn't seem too difficult to completely remake them, assuming that you could find the proper vinyl.
There is a fabric cover foam pad that is stiched into the backside of the vinyl. I own a sewing machine, although I'm definitly not "experienced", I'm certain that even I could replicate that pattern or do some other nice custom ones.

I actually had the pockets off for a while, I'm rebuilding those too. Although I am very tempted to buy those FG ones, I'm not sure if I want to go through the trouble of making the molds.

keitho64 · keitho64's Garage

toyboy

The part numbers are:

pull-straps 964 555 832 00 N13 (1 for each door)
(N13 is the colorcode for red, but these also come in black or blue) about $35/each

strap-guides 964 555 761 00 01C (1 for each door) about $6. each

johnnyo200 · 12-31-2002, 11:12 AM

Rick, the lexan was 3/16" thick, I didn't see the need for anything thicker. Like I said lexan won't crack like plexi. (I know "lexan" is a brand name)

I haven't weighed the completed panel yet, but the lexan was much lighter than the original fiberboard. I will weigh them tonite when I get home.
Honestly though, you could probably hit the panels with a hole saw to lighten it.

johnnyo200 · 01-03-2003, 11:13 AM

For those of you who were curious about the weight of the lexan door panels they are slightly lighter, weighing in at 2.45lbs as opposed to 2.5 for the original fiber/press board.

Sorry it took so long to respond.
How much extra horsepower is that? Haha!

bhuey · 01-26-2003, 04:55 PM

How well did the vinyl skin attach to the lexan? Did you just glue it down? I am in the middle of 'refreshing' my interior so any suggestions you can offer would be appreciated!

Thanks,
Bud

Evans, Marv · 01-26-2003, 05:16 PM

I did something similar for the door panels on my car. I went to a plastic supply place. They also sold to walk in customers. For $28, I bought a 4 ft. X 8 Ft. sheet of plastic that had a foam core and plastic sheet covering on each side. They cut the 4 X 8 sheet in half for me & I also used some of it to make a new rear package tray. Sight stuff, easy to work with & won't rot.

pwd72s · 01-26-2003, 05:24 PM

Great work guys! My congratulations. "Tightwad" is NOT a dirty word...not in this case.

Doug E · 01-26-2003, 06:48 PM

Nothing wrong with working smart (and cheap). Great job!

Langers · 04-13-2003, 04:22 PM

If you really want to save weight you could go quite a bit thinner with Lexan / Polycarbonate...I can vouch for the fact that it won't crack; just look at any remote control car!

Wil Ferch · 04-14-2003, 04:46 AM

Nice...
you *did*, however, still glue a sheet of plastic film as a vapor/water barrier on the door....right?....right?......

--Wil Ferch

Al G · 04-14-2003, 07:19 AM

I recall someone using corrugated plastic sheet last year for backing RS panels. Apparently very, very light and can be cut with a craft knife.

Al G

RickM · RickM's Garage

John, Curious how you cut the outline of your panel. Did you use a router or a lexan "knife" to score the sheet?

k9handler · 04-14-2003, 08:05 AM