door pocket fix with pix

[autovon]

When I bought my ’87 Cab a few months ago, the door pockets were broken and sagging (a problem I noticed on most 911s from the ‘70s to even the late ‘90s). After thinking about and researching on Pelican a fix that would last, be aesthetically pleasing, and inexpensive, here is what I came up with.

Items used:
- JB Weld (regular formula and NOT the Qwik Set)
- Aluminum rivets and washers
- Sheet metal blanks found at Lowe’s
- Sandpaper sponge used for roughing plastic parts before gluing and metal parts before painting
- Rubbing alcohol
- Medium-sized paper clips
- Rustoleum satin black spray paint

Repair Steps:
- After removing the door pockets, I found the driver’s side damage was much worse than the passenger’s side. I pulled back the vinyl to expose the area and used rubbing alcohol and a rag to remove the vinyl glue.
- I then cut the sheet metal to fit the areas needed reinforcement. This took some time to get the fitment correct. It is important to drill the mounting hole in the door pocket in the proper location so the screw that mounts the door pocket to the pull handle on the door lines up.
- I drilled the holes in the top sheet metal piece first, drilled into the plastic, and then the bottom sheet metal piece, ensuring everything lined up by placing rivets into the holes to hold the sheet metal pieces in place.
- After I was satisfied with fitment, I then roughed up the plastic and sheet metal pieces.
- I readied all the sheet metal parts, rivets, and washers, mixed the JB Weld (I used the regular formula so I would have time to install the rivets and washers; the Qwik Set cures in 5 or so minutes), and then began the installation process.
- I used medium-sized paper clips on the edges of the sheet metal to ensure the glue bonded well but made sure I didn’t squeeze a lot out between the sheet metal and plastic.
- After allowing the glue to dry overnight, I taped the areas to be painted and roughed up the metal.
- I used Rustoleum satin black spray paint on all exposed metal surfaces.
- I then installed the door pockets back on the doors. I had to use a small metal file in the mounting holes, removing small amounts of material until the mounting screw matched up in the door pull handle. I also used a medium-sized washer that I had painted black to reinforce the area even more.
- The passenger side door pocket is very solid and fits flush. The driver’s side door pocket is still a bit bowed but is very solid. I may take the advice of a Pelican member and get the fiberboard wet and then use a 2X4 cross member to return the original fitment of the door pocket. I hope this helps someone out.

- von

[SCWDP911]

nice... anyone know how to make the covers flat again?

[slodave]

Originally posted by v8_ranch
nice... anyone know how to make the covers flat again?

There seems to be a metal insert in the lids. I was able to reform mine. Taking it off of the door makes it easier.

Dave

[SCWDP911]

Thanks Dave. I will have to give that a try this weekend...

[Paulporsche]

Nice job.

[on-ramp]

very cool.

However, isn't that a lot of work for what you gain?

[autovon]

I suppose the amount of work vs. what you gain is relative (like truth... just kidding... sort of). I'm a little more handy with these types of fixes vs. strictly engine type fixes, so it is worth it to me. Since this is my first P-car, I'm kind of learning and teaching myself as I go and taking small bites, so to speak.

- von

[defcon65]

No pics, but I just did a similar repair myself to close up a crack where the pocket attaches to the door handle with a single screw. I used aluminum coil stock both sides cut to fit, epoxied and clamped in place. Then I put two pop rivets through it on either side of the crack. Bootstrap, but effective.

[81SCTarga]

Great writeup on something i will be doing in the future.

Thanks

[Kemo]

good job. excellent bang for the buck. looks great and I dont think anyone would be able notice the repair unless they were looking for it.

as far as reshaping the pocket, I have heard that you can get them wet and reshape them. I havent been able to visualize the procedure. I imagine you would just need to get a block of wood cut to the right thickness, maybe use the passenger side as a test bed. Then soak the the pocket down real good and put a piece of ply wood between the pocket and the car seat. Wedge in something to keep it pressed up against the pocket and I think it would do the trick. i need to do this anyway, so maybe when I get a free weekend, Ill try it.

[herr_oberst]

Originally posted by defcon65
No pics, but I just did a similar repair myself to close up a crack where the pocket attaches to the door handle with a single screw. I used aluminum coil stock both sides cut to fit, epoxied and clamped in place. Then I put two pop rivets through it on either side of the crack. Bootstrap, but effective.

Same problem with mine, I epoxied a piece of plastic to the cover the crack and then contact cemented a small piece of black nauga cut to fit. It's worked for three years, and you can't even see it.

I guess some previous owner must have used the door pocket to close the door, or something.