RS style door pannels, a fiberglass project

[Dave Colangelo]

So i have pretty much had it with the stock door panels in my 78SC. The fabric is not in bad shape but they are starting to fall off and the particle board behind it is getting saggy. I never use the map pockets or the hatches in the side, and the handles stretch when you pull the door shut. The thing that i really cant take is the door latches on the inside. The plastic grommets that hold the little metal arms in are falling apart and need to be replaced and the arms them selves are all miss aligned.

So here is what im going to do, get some very thing high density foam in a sheet of at least 4X4, trace the current panel, cut the foam out, and lay up fiber glass over it. Then finish it off and paint it nicely. I have not figured out what im going to do in terms of handles yet, I have to check what kind of metal ones I can get.

I have decided to go for the red fabric door handles I have always liked them. My question is how do you secure them to the door opening mechanism. I can get creative but is there some kind of accepted method for this. I will be getting the fabric and making them my self.

Feel free to make suggestions on techniques/things to do, if you have done this before feel free to make suggestions as to things you have done.

I will be posting pictures tomorrow when I start the project, as well feel free to follow this build it could get interesting.

Regards
Dave

[drcoastline]

Dave I can't comment to much on the pulls or the opening mechanism, but I would think the RS style probably mount to some fastener that is stock on the door?

As a suggestion for your new door panel. You could save your self a few steps and maybe a little dinero buy buying a fiberglass sheet and just cut out the panel. Lowes and HD both sell fiberglass sheets in 4X8. They are in the paneling. Good luck and I will be following your thread.

DR.

[JeremyD]

I did this Dave in my project... Fiberglass panels - and custom pulls from an austin healy - I hat the cheap plastic RSR door pulls

[al lkosmal]

Dave,
You can buy the RS hardware kit, which includes the door pulls, hardware, trim, etc. from Appbiz. That is what I did, when I made my panels. Pelican has this kit for example

. http://www.pelicanparts.com/cgi-bin/smart/more_info.cgi?pn=PEL-APBZ-DP9RDIY&catalog_description=RS%20America%20Style%20Door%20 Panel%20Do-it-Yourself%20Kit%2C%20instructions%20included%2C%20p air%2C%20911%20%281965-73%29

regards,
al

[Dave Colangelo]

hey guys thanks for all the suggestions so far.

I did see those kits on pelican, i though they were a bit pricey for what they were. The only thing i could see my self ordering is the metal handles from appbiz. The red fabric pulls are no issue for me to make and the finishing screws are easy enough to get a hold of. Im off to home depot today to take a look at fiber glass stuff, ill check out that board they have and see if it suits what i need. I will most likely end up with the foam and just wet lay the glass over it.

Regards
Dave

[Dave Colangelo]

With the template cut i prepaired for the first layer of glass



First layer of glass applied and mostly dry.




The back side layer is drying as I write this. More photos soon.

Regards
Dave

[pksystems]

subb'd

I plan to do something similar....

Borrow the glass coffee table top, wax it up, and put down like 4 layers of CF. Soak it in resin, and squeegee out all air bubbles. Once it drys trim it to fit, and the side that was against the glass should be almost perfect.

[Cory M]

I've done similar panels for hot rods but I just cut a sheet of 1/8" luan hardwood, drilled and pressed in generic metal door panel clips, and glued 1/4" closed cell foam to it (lightly sand both sides of foam first). I used 3M interior glue in a spray can. Glue and wrap with fabric of your choice. Let it dry and you are good to go. Mine still look good 10 years later.

[Lukesportsman]

WEVO makes some really nice handles too. I'm debating the issue.

[Dave Colangelo]

Both panels have been laid up, im just doing the edges now, Ill post some pics tomorrow. I will also be heading out to go get some red strap for the door pulls and I think im going to use the same strap to make the handles as well. I do like the look of the metal ones but im trying to keep this project as cost effective as I can and i think they fabric ones could look cool.

Any suggestions for fabric to cover it with, I will most likely go for some kind of generic black fabric, I have to go out and see whats available.

Regards
Dave

[Dublinoh]

I would think some sort of vinyl in black would be good...avoid too obvious a pattern

[Dave Colangelo]

So I finally got back to work today. The glass finished curing and I was away but here is what i have so far.

I put a coat of primer on them just for some protection, I will be upholstering them I guess the paint was unnecessary but what ever.


Here i is in the car. Still not upholstered, I have to go find fabric tomorrow but I wanted to size up all the holes and mount the handels and every thing. Every thing is coming together nicely and should be done in the next day or so.


Regards
Dave

[Dave Colangelo]

So I know its been some time since I updated this but the project is finished. There was one issue, I did not realize that the door panels had to go inside the weather seals. The issue is that when the door is closed the panel rubs on the seal and squeaks a bit. It also makes it so that you have to really pull the door shut. Depending on how much of an issue this inevitably creates I may make new panels. Any way here are some pics of the finished product.





Regards
Dave

[Lukesportsman]

So, what exactly does the pull for the latch connect to in the stock linkage? Just wondering as I've looked at my 72 and wasn't certain with what would stay and where a strap would connect. Thanks

[uncle_scott]

Originally Posted by Lukesportsman

So, what exactly does the pull for the latch connect to in the stock linkage? Just wondering as I've looked at my 72 and wasn't certain with what would stay and where a strap would connect. Thanks

The stock linkage comes out of the mechanism leaving a hole. You can use a small botl and but to attach your door pulls. Works great.

[Dave Colangelo]

+1, I drooped a standard #6 though the hole I dont remember the length. I then used a brass fitting I found at a hardware store that was about 1/4 of an inch tall, it slipped over the bolt so the fabric does not rub on the threads and rip. I then used one of those locking nuts so it does not spin its way off, It has worked real nice so far.

Regards
Dave