New Door Card Panels on the Cheap

74-911 · 08-07-2015, 06:48 AM

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....:

2jmotorsports · 2jmotorsports's Garage

Awesome thanks for sharing. I have one good door card and one severely warped card so I may try this in the near future.

NYNick · NYNick's Garage

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.

74-911 · 08-07-2015, 12:11 PM

Quote:

Originally Posted by NYNick

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.

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.