Unfortunately I didn't take pics of the door during installation. I had to install a new window regulator and replace the window seals and it seemed like a good time to repair the door panel.
I used 1/8" masonite. The panel weighs about 3lbs with the spar urethane. I didn't check the original, but I'd say it added a couple ounces, not worth mentioning. The staples were the tough part. I couldn't find any 1/8" staples, so I took my Arrow staple gun staples, put some tape across them, and cut them 1/8" with my dremmel cut off wheels. I used the 3M spray adhesive with the staples. The staples seemed to hold well with the 3M adhesive.
The vapor barrier is just thin plastic sheeting from home depot, attached with 3M spray adhesive to the door before installing the finished panel. I used this shelf liner material from home depot to replace the factory foam backing between the masonite and vinyl. All done on a warm summer day when the vinyl was soft and strechable.
