The $14.57 RS Door Card Project

[Dueller]

The motor is out of my '87 Carrera for some freshening and I didn't have anything to tinker with so I decided to give my interior a little attention. Its tan but my plans were to do a rear seat delete and change the interior to black.

I was reminded today given the near 100% humidity and 95 degrees that I live in the south and a black interior is a real heat sink....so maybe tan it would remain. Got to thinking about RS style door cards ....mine are pretty tired.....and on a lark decided to see what I could do. Appbiz makes some great products and I'm sure their product is worth every penny. But curious as to what I could do on a budget.

So I decided to head out on a materials mission.

First stop Lowe's. Picked up a 4'X8'X1/8" sheet of fiberboard. Had them cut into tw0 18'X48" pieces on their arm saw. I'll find a use for the rest. Atleast I'd have two straight cuts. Price: $9.01.

Meandered over to the hardware department....Picked up 10 black screws/grommets and two 1 1/2" metal hole plugs. Price $5.56

Had to make a Harbor Freight run and picked up a box of 12 D-ring faux carabiners. Price: $2.99

On to Hancock Fabrics. Bought 1 yard of red 1" webbing and 1/2 yard of black 2" webbing. Price $4.00.

All that stuff:



I used my old tired card as a template. I was even able to locate and mark screw holes so they would line up on the door:





Cut 'em out and test fitted:



For the door opener strap surround, I used a dremel tool and cut a slot in the 1 1/2" metal plug. Cut the card opening with a 1 1/2" paddle bit. Will paint that semi gloss black.

I pondered my options as far as the door pull handle. I could order plastic one from Appbiz for $38.00 a pair or Aluminum billet from WEVO for $180.00 a pair. Either way they sometimes cause the fabric to "pucker" around the mounting point. I wanted something simple and light so I attached 2" black webbing to the bolts hidden by the top door trim piece where the stock door handle attached. Threaded a black 3 1/2" fake carabiner D-ring thru it. Works pretty good actually. Since its attached to the door and not the door card its pretty sturdy. Maybe later I'll spring for a set of real forged climbing carabiners later but that can wait. Oh yeah I decided to eliminate the big round door lock knob and will not have speakers in the doors. Still have to trim a little more for the power window button.




Obviously not upholstered yet. The 1/8 " fiberboard is slightly thicker than the factory door card but not so much that it doesn't work. If anything its a little sturdier and does not "wave." Now its just whether I'll get some tan matching marine grad vinyl or spring for real leather!

Soooo....maybe homemade but here's the tally:

1/2 sheet 1/8" fiberboard $4.51
2 1 1/2"metal plugs $2.78
10 screws w/grommets $2.78
1 & 2" webbing $4.00
D-rings $.50

Total $14.57

Quite honestly it took me longer to run around gathering materials than it did to make one card. Keep ya posted on the project.

[Uncle Enzo]

Love it. Keep it coming .

[kach22i]

Looks like you still have to do the other door, can you get these on a scale?

And weigh your old combination while you are at it.

Isn't the whole point of the RS look to save weight?

Thank you for posting, very interesting project.

I wonder if you could get the weigh down even more with use of a drill or hole saw.

[Dueller]

Thanks, Uncle E.

Will do, kach. When you consider the weight of the stock door mechanisn, the arm rest and door pockets it's clearly lighter. Right now I'm pondering options to use in place of the modified hole plug to trim out the door latch strap.

Ideas anyone?

[Dueller]

Well, I hit it with some black spray paint. Maybe it will look OK when card is upholstered.

[jpnovak]

Now head over to a JoAnne Fabric store and get 2 yards of headliner foam and vinyl of your choice. Mount the headliner foam with spray adhesive. Then wrap in vinyl pulling edges tight and glue and staple on the backside. Easy. Do the same for the rest of your panels in the rear and they will all match. You should be able to redo your interior for less than $100 total - especially if you use the 40% coupons.

[Dueller]

Hey. Jamie....actually I've found 6 square yards of tan leather that I can get for about $180...enough to do front and rear with some left over. I'm using after market seats that are complimentary so I won't have to upholster them. Smelsl wonderful combined with the vintage Porsche odor. Lol.

[HawgRyder]

I did the same idea to my 69S.
But I used plastic board that looks like cardboard (corregated) so that it was waterproof.
Good job on yours BTW.
Bob

[Uncle Enzo]

My only fear with these cards or any RS cards is what to do when the wind picks up and tries to blow the door open. We have all had that moment where we thought the door was going to be ripped off. What do you grab in a panic?

[Tippy]

I did the same idea to my 69S.

But I used plastic board that looks like cardboard (corregated) so that it was waterproof.

Good job on yours BTW.

Bob

I'm so going to do that to mine. Thanks for the idea.

[porsche4life]

Looks good Jim!

What color climbing biners do you want? I'll keep my eye out when I hit the sale racks for ya, or I might find some that are used and being retired...

[Dueller]

Originally Posted by HawgRyder

I did the same idea to my 69S.
But I used plastic board that looks like cardboard (corregated) so that it wasw if waterproof.
Good job on yours BTW.
Bob

Bob, when I was on my material search I looked for plastic board but could only find 1/4" that seemed rigid enough but that seems to thick. The 1/8" appeared to flimsy. What kind did you get and where? As far as waterproof I did look a fiberboard Tha has one side cover in thin plastic that I may end up using. It was only $2 more.

Thanks, Sid. I'd like black measuring 3 or 4 inches long and flat instead round. Leat me know if you run across any. When I came up with the d-ring idea I actually thought about you being a climber. And I was At Harbor Freight shopping for a cheap tool like you!

Uncle E...that happened to me once in my wife's Oldsmobile. Sprung the door. But it was during Hurricane Katrina!

[Dueller]

Originally Posted by fthshhu

Looks like you still have to do the other door, can you get these on a scale?

Will do when I get the upholtery material on. I,m sure the actual cards are only a few ounces different. Only weights savings I can see is the elimination of factory door handle pull, door pockets,and speakers.

[tharbert]

I know you sourced some leather. I just wanted to add that I got leather for my steering wheel recovering job from STL Leather in St. Louis. I think a long strip of nice quality was $17. I found the storefront south of downtown off I-64 and just as you would imagine, they have stacks and stacks of pelts and hides. It's run by a little Chinese lady that reminds me of "Why You Always Bring Me Junk?" Sue from Gas Monkey.

[kach22i]

I wonder if you could just spay the hardboard with black Plasti-Dip?

Might need a good primer.

[Dueller]

Originally Posted by kach22i

I wonder if you could just spay the hardboard with black Plasti-Dip?

Might need a good primer.

Might work. Obviously I'm gonna leave the plastic water barrier on the door. In any event the factory door card was just bare fiberboard and there were no significant signs of water damage.

[stormin48061]

Dueller, this is what it's all about.... easy to pay mucho deneros to R&R - anyone with a wallet can do that.. but you're the man, you make us guys proud to find an economical way to satisfactory repair stuff without giving up your first born for a car of passion. very nice and thanks for sharing.

[Jays72T]

Looking great, nice job.

[Dueller]

Storming And Jay...thanks for your comments. I could afford to purchase aftermarket cards pre-cut with all the hardware but what fun would that be?

Received my leather and it gorgeous and luxurious. So nice I really don't want my homemade hardware to look cheesy.....particlearly the trim surround on the door latch trim o around the red strap.

Anybody have any suggestions?

[josborn10]

On a similiar project, I 'spray-glued' the fabric down and then used a razor blade to cut the fabric and board. It looked clean and no wrinkles.

Be sure to wear gloves with that glue otherwise you will be pulling your hair out... literally.