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Bollweevil
Join Date: Dec 2003
Location: Fulshear, Texanistan
Posts: 3,361
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New Door Card Panels on the Cheap
The original vinyl covers on the door panels were in good shape but the cards themselves had seen better days so....
Materials: 2' x 4' 1/8" tempered hardboard from HDepot - 1 for each door 3' x 5' closed cell dense foam from a local trim shop (approx. 1/12" thick?) 3M Super 77 spray adhesive T-50 1/4" staples and staple gun generic panel clips from FLAPS - 6 Total materials cost: about $25... Tools: Sabre Saw w/good blade utility knife drill with various sized bits and paddle bits hole punch scissors Old door card: ![]() Trace the old card onto the hardboard and cut out then drill out the required holes. ![]() Trace the new card onto the foam and cut it and the necessary holes for the speakers, etc. A hole punch makes quick work of the holes required for all the screws. Insert the 3 generic panel clips in their holes, spray the card with the 77 adhesive and carefully place the foam on the card. ![]() Staple the vinyl to the card using the 1/4" T-50 staples. (forgot to take picture?) If necessary, install a new plastic vapor barrier on the door frame and the new door p[anel is now ready to install....: ![]()
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Jack 74 911 Coupe 2.7L - K21 Option - S suspension |
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Perpetual Reassembler
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Awesome thanks for sharing. I have one good door card and one severely warped card so I may try this in the near future.
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Troll Hunter
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Consider different door card covers if you're going to all this trouble. Local fabric stores can be a great inspiration. One I saw here had a Scottish Plaid. I loved that, but you could do black suede, leather etc.
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1978 SC Coupe, Gris Argent Metallic Silver 1988 FJ62 Blue/Gray 2020 M2 CS |
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Bollweevil
Join Date: Dec 2003
Location: Fulshear, Texanistan
Posts: 3,361
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Trying (for the time being anyway) to keep the interior original and the original vinyl is still in very good condition. Doesn't show in the picture but the armrest and pocket are black and the panel cover itself is dark blue. May well change it as you suggest sometime in the future however.
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Jack 74 911 Coupe 2.7L - K21 Option - S suspension |
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