Cheap and nice door panels

[datmo]

make some door panels if you don't have any.
They're nice and easy and can do it with just about any material you want.

materials
hemp boards. it's $10 a board and prob need 2 boards for all of em.
black vinyl. it was $12 for 9 yards? MORE THAN ENOUGH form joannes
cushion. get some sponge from a local upholstery shop or micheals. ( i already had some so didnt really search) its the stuff people put on couches or beds.
staples + staple gun. get the smallest staples from homedepot and sand em down halfway.
3m adhesive form home depot.
heat gun.



try getting a beaten up door panel that you have and replicate the size and shape.
cut the hemp boards to check the size and fit of the door panel. cut all holes of course. make sure you skim a bit short because the vinyl is extra thick.
get the vinyl out and let it lay in the sun to stretch. also heat gun after to get all stretches out.
get sponge and spray adhesive on it then lay on the rough sides of the board.
then adhesive sponge onto vinyl and heat gun it.
then pull on the vinyl around the wood and staple with thin staples so it grips the board but not poke through the vinyl.
when you slide them into the metal piece on the inside of a door, they may not fit. to widen, just get a screw driver and push in and through to widen.
then put in your car. and feels great.
I have some pics in my thread but here. was $60 total for me and got all four done and satisfied. I also had enough to do my kickers.
I have enough to finish my rear dash pad if i ever get to it.

BEFORE HAND. PLEASE EXCUSE MY CRAPPY PICS. MY PHONE ISN'T THE GREATEST

Here's the test fit.


here's the layering. vinyl on the bottom. cushion, then hemp board.


here's the completed product.


here's what they look like installed.


I made my kickers. a little beat up but because i let shit rest on it and it recovered.

I also didn't have any inner side skirts if you know what I'm speaking of.
Using the same method. except i just stapled the top because the vinyl was too thick for the aluminum, I made some.
pics there's a bit of lighting like i messed up around that bump but you just have to make slit on the bottom so the vinyl doesn't gather up.


hope this benefits anyone.

[flatcat19]

Those look good.


Good info.
I vote to move this to the How-To section.

[datmo]

Those look good.


Good info.
I vote to move this to the How-To section.

Thanks. I thought i did post it there?

[flatcat19]

You're cool.

The mods will get it moved for ya.


Those did turn out great.

[datmo]

Thanks man. I didnt have enough money to buy new ones so did what a brotha could. haha

[RedBanner]

Awsome man. Great writeup, +1 for sure!

[Indy510]

When I did this years ago, I didn't use any padding .... .. but the Vynil was much thicker than the stock door panel material

and I had to bend the metal strip at the top of the door to fit the thicker door panels .. . did you have to "open up" that red strip at the top of the door panel?

[datmo]

When I did this years ago, I didn't use any padding .... .. but the Vynil was much thicker than the stock door panel material

and I had to bend the metal strip at the top of the door to fit the thicker door panels .. . did you have to "open up" that red strip at the top of the door panel?

Yeah. I wrote in the directions that if people get thick vinyl, they should widen them.
I chose to stick with thinner vinyl. I kinda regret it but it was cheap as hell the other vynl was too thick.

[Laecaon]

Thick vinyl, just dont foam the top 1/4"-3/8" of the panel, done.

[Devious620]

Made Mine Out Of 1/4" Mdf And CF Dinoc. Turned Out Ok I Think.

[datmo]

Made Mine Out Of 1/4" Mdf And CF Dinoc. Turned Out Ok I Think.

Look good man,
Good shit.

[MicroMachinery]

Nice. Thanks for the write-up.

[KlassicMotion]

Nice write-up.

I might add; You don't always need the staples when using the contact adhesive. Just make sure you follow the instructions on the can. Though they don't hurt. Just another cost cutting option.

If you can use an automotive grade upholstery foam like the one in the picture (from National fabric), It won't give you the "puffy" look. It comes in 1/8" and 1/4" thickness. For cost cutting ideas, get a buddy or two to chip in and split the cost if you have to have it shipped.

For application of the black foam; apply the glue to the board and an over-sized piece of foam, wait 5 minutes, then lay the foam down on the board starting at one end and smoothing the foam while holding the other end in the air as you go. Trim the excess foam off to the edge of the board. Do the same with the vinyl layer, but leave the excess to wrap around the edge. This technique will give you a tight/solid look. Spray your glue on the back of the panel and the excess vinyl, wait 5 minutes, and pull the excess around to the back side... I hope that makes sense...

Here is the pic of the glue and foam, and a couple pics of my work for credibility: (I would have made some styling changes to the door panel, but the customer wanted it that way)...

[datmo]

man those look good. put mine to shame.
thanks!

[KlassicMotion]

Rock yours for now. I'm sure they look better than what was there. Then when you get everything else sorted, pick up some 1/4" dense foam and redo them... Cars are like a revolving extension of our personalities... and wallet. Our money situation changes, and our personalities change, and there is no reason our cars shouldn't follow suit.

[izzo]

+500

[datmo]

you win

[510freak]

+500

And ad +1000


Nice work Kyle

[KlassicMotion]

Thanks.
Like I said I would have done it a bit differently if it were mine, but "the customer gets what the customer wants"

[510freak]

You make it look so easy