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Bollweevil
 
Join Date: Dec 2003
Location: Fulshear, Texanistan
Posts: 3,361
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
Old 08-07-2015, 06:48 AM
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Perpetual Reassembler
 
2jmotorsports's Avatar
 
Join Date: May 2010
Location: Orange County
Posts: 1,037
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.
Old 08-07-2015, 11:33 AM
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Troll Hunter
 
Join Date: Apr 2013
Location: on the river
Posts: 4,732
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.
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1978 SC Coupe, Gris Argent Metallic Silver
1988 FJ62 Blue/Gray
2020 M2 CS
Old 08-07-2015, 12:02 PM
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Bollweevil
 
Join Date: Dec 2003
Location: Fulshear, Texanistan
Posts: 3,361
Quote:
Originally Posted by NYNick View Post
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.

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Jack
74 911 Coupe
2.7L - K21 Option - S suspension
Old 08-07-2015, 12:11 PM
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