Revhead
08-12-2004, 10:15 PM
Doing door panels on a very small budget. Alot of people already know all this info, but for the guys new to this hobby, this one is for you. This works on flat simple door panels.
This is what my door panels looked like when I started.
http://www.cliftongarage.com/images/doorpanel/100_2707.jpg
To make a new panel you can use 1/8th inch MDF. It's available at almost all hardware stores and costs something like $20 for a 6x8 sheet. I think it may even be less.
Use what's left of your old panel or the door for a template and trace out the pattern. I use a jigsaw to cut the pattern. I've tried a rotozip and it is slow and burns the MDF alot. Also cut out door handle and window winder holes now.
To cover the patten I used some vinyl that I bought at a local fabric store. It has a thin mesh backing. DO not get the stuff with a felt backing. It will look ugly at the corners and be hard to glue down.
I used Permatex 27828 healiner and carpet spray glue. It worked great. I tried contact cement and had no luck.
Permatex 27828 (http://www.permatex.com/auto/autoint.asp?automotive=yes&f_call=get_item&item_no =27828)
http://www.cliftongarage.com/images/doorpanel/permatex.jpg
I layed the vinyl on a piece of carboard and sprayed it down with the glue. I covered the panel in glue too. Then you lay the panel down onto the vinyl. once the glue has taken hold, pick it up and make sure there are no bubbles. I let this dry for the rest of the evening and left the edges for later.
To do the edges you pick a middle section to start and work your way around. spray glue on both the backside of the panel and the extra material hanging off the edge. Once the glue is ready is ready (according to can), fold the material over the edge of the panel. Don't pull hard or stretch it cause it'll pop back off later, but make sure it is smooth. On the corners you work in one direction. Once it is folded, pick up the next portion of vinyl and fold it towards the center of the panel, you might have to slit it for it to lay flat. It's hard to describe the process, so my advice is figure out the corner folds before glue is applied and you be fine.
Once the panel is all glued down let it dry. Make sure you got plenty of glue around trim holes, window winder holes, etc. Once the panel is dry you can punchout the holes for the trim and window/door handles. Be careful with drills, they catch and pull the vinyl.
Here's how mine came out.
http://www.cliftongarage.com/images/doorpanel/100_2702.jpg
My original door panel was held on with flimsy clips that easily tore the carboard they were attached to. I decided to improvise. I haven't finished the project yet, but here's what I have so far.
For the vertical edges I am using the trim screws with the trim-specific washers.
for the lower edge that always seems to get messed up I came up with a solution.
At the hardware store I found some threshold molding that was narrow and long. It came in 5" length for about $6. It is ribbed and has a slight fold in it. Here's what it looks like
http://www.cliftongarage.com/images/doorpanel/100_2704.jpg
I cut it to length, polished it, and painted between the ribs with black spray paint. It really transformed the look from a household item to almost a factory looking automotive trim. The ends still need to be rounded off.
Here's it stuck to the door with tape, but you get the idea.
http://www.cliftongarage.com/images/doorpanel/100_2705.jpg
and that's about it. I think I have less than $25 in the 2 front door panels. If I left something out or ya got questions, let me know.
This is what my door panels looked like when I started.
http://www.cliftongarage.com/images/doorpanel/100_2707.jpg
To make a new panel you can use 1/8th inch MDF. It's available at almost all hardware stores and costs something like $20 for a 6x8 sheet. I think it may even be less.
Use what's left of your old panel or the door for a template and trace out the pattern. I use a jigsaw to cut the pattern. I've tried a rotozip and it is slow and burns the MDF alot. Also cut out door handle and window winder holes now.
To cover the patten I used some vinyl that I bought at a local fabric store. It has a thin mesh backing. DO not get the stuff with a felt backing. It will look ugly at the corners and be hard to glue down.
I used Permatex 27828 healiner and carpet spray glue. It worked great. I tried contact cement and had no luck.
Permatex 27828 (http://www.permatex.com/auto/autoint.asp?automotive=yes&f_call=get_item&item_no =27828)
http://www.cliftongarage.com/images/doorpanel/permatex.jpg
I layed the vinyl on a piece of carboard and sprayed it down with the glue. I covered the panel in glue too. Then you lay the panel down onto the vinyl. once the glue has taken hold, pick it up and make sure there are no bubbles. I let this dry for the rest of the evening and left the edges for later.
To do the edges you pick a middle section to start and work your way around. spray glue on both the backside of the panel and the extra material hanging off the edge. Once the glue is ready is ready (according to can), fold the material over the edge of the panel. Don't pull hard or stretch it cause it'll pop back off later, but make sure it is smooth. On the corners you work in one direction. Once it is folded, pick up the next portion of vinyl and fold it towards the center of the panel, you might have to slit it for it to lay flat. It's hard to describe the process, so my advice is figure out the corner folds before glue is applied and you be fine.
Once the panel is all glued down let it dry. Make sure you got plenty of glue around trim holes, window winder holes, etc. Once the panel is dry you can punchout the holes for the trim and window/door handles. Be careful with drills, they catch and pull the vinyl.
Here's how mine came out.
http://www.cliftongarage.com/images/doorpanel/100_2702.jpg
My original door panel was held on with flimsy clips that easily tore the carboard they were attached to. I decided to improvise. I haven't finished the project yet, but here's what I have so far.
For the vertical edges I am using the trim screws with the trim-specific washers.
for the lower edge that always seems to get messed up I came up with a solution.
At the hardware store I found some threshold molding that was narrow and long. It came in 5" length for about $6. It is ribbed and has a slight fold in it. Here's what it looks like
http://www.cliftongarage.com/images/doorpanel/100_2704.jpg
I cut it to length, polished it, and painted between the ribs with black spray paint. It really transformed the look from a household item to almost a factory looking automotive trim. The ends still need to be rounded off.
Here's it stuck to the door with tape, but you get the idea.
http://www.cliftongarage.com/images/doorpanel/100_2705.jpg
and that's about it. I think I have less than $25 in the 2 front door panels. If I left something out or ya got questions, let me know.