DIY Door Panel Basics
There are a couple good how-to guides on Pelican Parts and Rennlist if you search around, but I really didn’t find anyone using tartan wool to make an RS-style panel. So I’m hoping this post adds to the information currently out there. One good resource for a budget Carerra RS backdate is David Pengilly’s YouTube channel, with door panel here:
https://youtu.be/fFRVnzVIpuI
Definitely cool to see a hobbyist doing major surgery on a Porsche fairly successfully and on a budget!
The first step was sourcing the materials I needed. The door panels themselves are ordinary 3mm hardboard from Home Depot, wrapped with 10mm upholstery foam and tartan fabric. From AppBiz, I procured the “welt bead” rubber trim for the fronts and backs of the doors, as well as the bezels for the electric window switches.
For fabric, I ordered a few yards of medium weight (10 oz. I think) wool tartan through the Highland Scottish Gift Shop in Calgary (
Scottish Gift Shoppe: Celtic Weddings | Scottish Formal Kilts). I initially thought I should use heavy weight fabric, but apparently the medium weight is what they advise people to use for furniture upholstery, and it was definitely easier to work with than heavy weight fabric. The tartan is Ancient Campbell, in keeping with my family heritage, of course!
In summary, the tools and materials you will need are as follows:
- 3mm harboard
- 10mm upholstery foam
- fabric/leather/vinyl to cover the panels
- Carrera RS door pulls and door opener straps
- rubber “welt bead” edging
- window switch bezels (you can try to re-use the on your existing panels, but you will most likely destroy them when removing them)
- electric drill and assorted bits
- 2 ¼ inch hole saw to cut the hole for the door lock mechanism
- utility knife
- staple gun and staples
- die grinder or file/sandpaper
- nutsert tool, nutserts, and metric countersunk machine screws
- fabric punches and hardwood block
- 3M spray adhesive
- fabric glue
- stop fray fluid
- serger machine
I should also mention that AppBiz sells an entire DIY kit for this, which could be helpful! Also, rather than using the actual Carerra RS door pulls and openers, I had fellow Pelican SD Swede make me a set of his straps, in distressed black leather with brass grommets. Here's his thread with examples of his work:
http://forums.pelicanparts.com/porsche-911-used-parts-sale-wanted/841915-custom-leather-rs-panel-door-pulls-check-straps.html