A couple of people on my dash build post wanted to know how I made my door panels so I`m going to post some pictures of the progress.
First I cut out the shape from a 1/4" piece of birch plywood.
Then I cut out the holes for the lock lever and the grab handle and cut out my shapes for the insert
Next I drill a 1" hole about 1/2 way through to mount the clips. Notice I drill on the edge of my mark so the clips when installed will line up with the stock ones
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10:29 PM
PFF
System Bot
TXGOOD Member
Posts: 5410 From: Austin, Texas Registered: Feb 2006
Next, I cut the stock panel right under the groove. Don`t mind my crooked cut, it won`t be seen.
It fits right on top of the plywood. I forgot to mention that you have to cut the plywood shorter by the piece that goes on top so the overall will be right.
Then I drill holes for rivets. I`m using 1/8" rivets 1/2" long and drilling 9/64" hole for them to go into.
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10:34 PM
TXGOOD Member
Posts: 5410 From: Austin, Texas Registered: Feb 2006
I just took the measurements from the edges of the stock doors panels to the middle of the existing plastic clips and transfered measurements from there. The new panel, because of the flatness of it and that it doesn`t have raised places where the clips go is that it actually is up against the door tighter. I still need to bend the lock rod because it kind of rubs against the back of the panel. To use these clips, which I like better than the plastic ones because they release easier, you have to drill the holes, where they go, out to 3/8". The only thing I might do different on this panel, that I didn`t do on the first one, is use small wire instead of rivets to hold the panel to the stock top part of the panel because unless you get the rivets away from the edge of the plywood enough it tends to flare out when you install the rivet.
Trace the wood insert out on the foam making it about 1/8" bigger all of the way around.
Then drill a number of 3/4" holes just deep enough for the 10-24 x 5/16 t-nuts to sit flush when driven into the plywood.
Next mark through the t-nuts and drill holes large enough for the t-nuts to fit through the panel. Also drill a hole just at the ends of the inserts. Later you will pull the vinyl through that hole and staple it on the backside to secure
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11:01 PM
PFF
System Bot
TXGOOD Member
Posts: 5410 From: Austin, Texas Registered: Feb 2006
Lay panel on vinyl face side down and start stapling vinyl to back with 1/4" staples. Start from the middle and pull out slightly toward the ends along one edge until you get it stapled about 1" from the corners.
Then flip panel around and do the same from the opposite side pulling vinyl fairly tight until you finish that side. You can staple the corners now. If you start to staple around the corner and let it overlap as you go you can pull it tight enough that all of the wrinkles will be on the backside and hidden.
Then I stick the end of a pencil through the t-nut holes and cut around with a razor.
[This message has been edited by TXGOOD (edited 05-03-2007).]
