Door Panel Recover

Effie · Post by **Effie** » June 15, 2009, 9:37 am

Ok, I saw a thread or a link to a site on here somewhere, where a fella recovered his door panels.

I can't find it now.

I even searched. Anyhow, I went and bought some vinyl at the piece goods shop and now I'm wondering, what kinda sturdy something can I use to make my backing for the panel? My old blue truck had some white plastic door panels that would work perfect, but I can only find one of them.

My brother has some thin sheet aluminum that might work, but I don't want to use his aluminum for something like that.

I think plexiglass would be too thick.

65 CREW · Post by **65 CREW** » June 15, 2009, 10:31 am

I think it is called Masonite, it is a pressed fiber board that is smooth and shiny on one side and sort of rough with a texture on the back. It comes is varying thicknesses. I have got it at Home Depot in the past.

36truck · Post by **36truck** » June 15, 2009, 10:32 am

I redid my 79 Bronco door panels & used Masonite panel to glue 1/2" foam & vinyl to it.

Gritsngumbo · Post by **Gritsngumbo** » June 15, 2009, 11:09 am

Effie: Uncle Skip made some out of thin aluminum. I believe there are pics and info in the Hints and Tips section. If not PM him and I'm sure he'll share. Using his idea, I have some cut out but haven't covered them or installed them. (I'll send a photo if you can't find his info.)

Effie · Post by **Effie** » June 15, 2009, 12:08 pm

Sweet! Thanks ya'll.

I'll look for Uncle Skip's thread and check out the masonite stuff, I need to go by Home Depot anyhow.

Gritsngumbo · Post by **Gritsngumbo** » June 15, 2009, 12:31 pm

If you're using the original door trim, I don't think the Masonite will work. IMO, it's much too thick to slide into the chrome trim. The repoped plastic ones and the aluminum ones are really thin. If you're just making up a door panel design, the Masonite will probably work OK.

Effie · Post by **Effie** » June 15, 2009, 12:44 pm

Yeah, that's what I was worried about. I want to use the chrome trim. I don't know if I'll be able to roll the vinyl over the edge, or if I'll just have to trim it flush and hope it doesn't pull away and out from under the trim.

It's the marine grade vinyl, not the other kinda with the felt/fuzzy backing, just vinyl, so its fairly thin...guess we'll see.

Gritsngumbo · Post by **Gritsngumbo** » June 15, 2009, 12:51 pm

I haven't gotten around to putting on the vinyl yet. It is going to be a challenge. I'm thinking of gluing the vinyl to the aluminum and then trimming to the edge. May have to open up the channel in the trim a little with a wide blade scraper (or something like) to make it fit. I have a set of black plastic inserts and I bought a can of vinyl paint and going to see how that works as I want the insert to be grey rather than black or red.

Effie · Post by **Effie** » June 15, 2009, 1:01 pm

Gritsngumbo wrote:I haven't gotten around to putting on the vinyl yet. It is going to be a challenge. I'm thinking of gluing the vinyl to the aluminum and then trimming to the edge. May have to open up the channel in the trim a little with a wide blade scraper (or something like) to make it fit.

That's exactly what I was thinkin. Great minds think alike.

willy3486 · Post by **willy3486** » June 15, 2009, 3:17 pm

I posted a how to on making them years ago on the old site. They were like the originals except using vinyl. What I did was I figured out the measurements of the originals as close as I could from photos. I have the measurements in my photos. I have a few there showing them. What you do is to put quilting batting on the vinyl and then fold it over and sew the pattern. The thickness of the the vinyl with the batting in the middle to fluf it out is the perfect thickness and easier to work with that aluminum to me. Make sure the vinyl that is folded is bigger than the door panel will be and fold it on the side toward the dash. I made a template on thick posterboard then I trimmed every other square out. That way you lay it on the vinyl and mark the vinyl with a washable sewing pin. I got the top curve by using the trim piece itself and I think the curve was a dime,nickel,or quarter. Just see which one looks the best. Then I trimmed to fit. Its stiff enough to hold but will bend to the contours. And its the right thickness to fit in the trim. You can look through my pics to see what they look like. If you want the better instructions I posted years ago let me know and I will post them. I think I saved a copy. If you don't hear from me send me a email if you want them. I don't hit the site much anymore so I may not know to post them.

willy3486 · Post by **willy3486** » June 15, 2009, 3:32 pm

Heres the link to my pics. I posted them 3 years ago and I originally posted them on the msn site probably 6-7 years ago if not longer. Look towards the bottom. I have had them on a few years now and they look as good if not better. That was right after I put them on. They have adjusted to the shape of the door and fit better than the photo.
http://fordtruk.com/forums/album.php?user_id=25

6166 Junkyard Dog · Post by **6166 Junkyard Dog** » June 15, 2009, 9:41 pm

No matter waht you do with door panels IF They are too thick,,, Door handles will not stay on and most likely fall off when opening close the door unless you also extend the shafts, those ridges on the shaft are there not just for looks see I have seen many that try to tighten on the splinne one that is done shaft is trashed then so make sure no matter what you use that the handle goes on all the way nothing is being embarrased than opening the door on your nice truck and handle falls off......

ezernut9mm · Post by **ezernut9mm** » June 15, 2009, 9:46 pm

i think it was 65thug. his wife did a set for his truck.

ezernut9mm · Post by **ezernut9mm** » June 15, 2009, 9:50 pm

ok it was 65f100thug.

http://www.fordtruk.com/forums/album_pi ... er_id=1380

modeleh · Post by **modeleh** » June 15, 2009, 9:56 pm

I used thin aluminum sheet, .026 I think it was, I used spray glue on the aluminum after cutting it using the original plastic one as a template. I wrapped the vinyl over the edge, and I was able to get the original trim over it, but it was a tight squeeze. I would say that it is important to use the aluminum because you have to "shape" it where there is a contour/bulge near the front edge of the door. I just bent it gently by hand, a little at a time until the panel fit the door nicely.

yes I know the door handle in the pic is for the other side.
I did the beer cooler pocket vinyl myself too, but it's really hard to sew that zipper in with the curve. The trim rings are made of .080 aluminum sheet then polished.

FORDMANLCRACKEL · Post by **FORDMANLCRACKEL** » June 15, 2009, 9:58 pm

I made these from alum. 1/4 inch foam padding and marine vinyl wraped around the edge to the back side. I did have to pry the trim open a little.
http://fordtruk.com/forums/album_pic.ph ... user_id=30
http://fordtruk.com/forums/album_pic.ph ... user_id=30
Headliner is made the same way.
http://fordtruk.com/forums/album_pic.ph ... user_id=30

Lonnie

6166 Junkyard Dog · Post by **6166 Junkyard Dog** » June 15, 2009, 10:00 pm

nice looking door pocket and trim

Gritsngumbo · Post by **Gritsngumbo** » June 15, 2009, 10:08 pm

Nice job Lonnie. I'm impressed. I need to get to work on mine. Think I'm going to use velcro to hold my trim pieces (and the panel) on, as I don't want to drill holes in my doors to mount them with the clips for fear I'd screw them up.

Post by **Greg D** » June 15, 2009, 10:38 pm

The repop inserts are pretty cheap for Black - more for White, Red, etc though. I have seen them on sale for about $30.

qwertyd10n · Post by **qwertyd10n** » June 15, 2009, 11:08 pm

FORDMANLCRACKEL wrote:I made these from alum. 1/4 inch foam padding and marine vinyl wraped around the edge to the back side. I did have to pry the trim open a little.
http://fordtruk.com/forums/album_pic.ph ... user_id=30
http://fordtruk.com/forums/album_pic.ph ... user_id=30
Headliner is made the same way.
http://fordtruk.com/forums/album_pic.ph ... user_id=30

Lonnie

Hey guys,

How does the chrome trim around the upper door panel attach to the door itself? I see only one screw hole per side up near the front on the top trim piece. There are clips that need holes drilled in the doors?

Cheers,
Dion