Mystery holes in door panel

[HenrikL]

I'm replacing the wavy masonite board in my door panels. I have disassembled the passenger door panel and found three holes in the board that I do not know if I should transfer them to the new board.

The hole for the second power window witch and the window winder I see no reason to transfer, but what about the other three in the picture below?

[vulcan300]

If nothing passes through them, you don't need to transfer them to the replacement door card you are making.

[HenrikL]

Ok, was just worried that the may have some function that I don't realize until it is time to install the new door panels on the car.

[Paulporsche]

Are you using Masonite, or some other material for the new door panels?

[theweaver]

Hi, Assuming that you are definitely replacing/remaking the panels, I would suggest that you remove all the material/leather from the donor panel.
Offer the old panel to your door, and check that the holes are not ' blind holes' , that fit over protruding screws, because if they are reqd and you do not cut them, obviously your new panels will not fit snugly against the metal door and bulge out.

The other holes as you quite rightly say are for universal application of alternative drive.

Furthermore, I found difficulty securing the plastic sealing trims which are fitted for and aft of the panels. They are stapled on, and I found difficulty finding any short enough to fit into my air stapler. The ones I used were about 2mm too long. The only way I could prevent the staples showing on the leather where they protruded was to fire them in at an angle. From memory, the staples need to be about 3.5mm long. I believe that you must use an upholstery staple gun, rather than the mechanical hand operated variety.

I would also suggest that you cut the holes in the material with a woodworking router if you have one. With a straight bit it will make a very clean hole, especially where the plastic panel poppers are used. Drills etc tend to leave a furry/ messy edge.

Also, as the panels are identical, use double sided tapes to secure two pieces of material together, and cut both pieces at the same time, including the holes you need. Possibly securing your donor panel to the pieces and use it as a perfect template.

To save wasted time, I suggest you try a variety of ideas prior to cutting the final piece.

Hope that helps, best of luck


Geoff

[HenrikL]

Originally Posted by Paulporsche

Are you using Masonite, or some other material for the new door panels?

Yes, the original seems to be 3 mm Masonite and I'm using that to replace it.

[HenrikL]

Originally Posted by theweaver

Offer the old panel to your door, and check that the holes are not ' blind holes' , that fit over protruding screws, because if they are reqd and you do not cut them, obviously your new panels will not fit snugly against the metal door and bulge out.

Great idea - will do that.

Originally Posted by theweaver

Furthermore, I found difficulty securing the plastic sealing trims which are fitted for and aft of the panels. They are stapled on, and I found difficulty finding any short enough to fit into my air stapler. The ones I used were about 2mm too long. The only way I could prevent the staples showing on the leather where they protruded was to fire them in at an angle. From memory, the staples need to be about 3.5mm long. I believe that you must use an upholstery staple gun, rather than the mechanical hand operated variety.

The shortest staples I have found are 6 mm, but a friend told me they can be slightly trimmed with a Dremel.

Originally Posted by theweaver

I would also suggest that you cut the holes in the material with a woodworking router if you have one. With a straight bit it will make a very clean hole, especially where the plastic panel poppers are used. Drills etc tend to leave a furry/ messy edge.

I think I can borrow a woodworking router and try this.

Thanks, lots of great info in your post!