door panels

[graham53]

My masonite door panels are not restorable. I have looked and searched to find replacements without any luck. I think after a lot of work i have a pattern to cut my own. I will be making them out of sintra ( 1/8" pvc sheet material) I know someone that will be cutting this pattern on his cnc router. If any are interested i will keep you up to date on how it working.

A 260z.pdf

[EScanlon]

David;

This is very interesting. You might post a picture of the finished item,as I'm sure there are others who may want to do the same. There might be some that would be interested in seeing if you would provide the same for them.

E

[graham53]

thanks E

I will have one put together soon and will post a picture

[TomoHawk]

Do you know how you will handle the fuzzy window strip along the top?

[graham53]

I will reuse the metal top, replace the masonite. Mine was stapled through the metal. I plan on using a small stainless rivet and grind it smooth on the back with my drimel

[RayR]

Can anyone recommend other options to securing the fuzzy strip? I'm ready to replace mine, would prefer to re-staple but have no idea how to staple thru the metal.

[LBO730]

I know this sounds questionable, but I used pop rivets on a restoration a few years back. I bought a strip of the fuzzy from a hot rod shop (Julians I believe) and cut it to fit. When the rivets are in place, there are kinda buried in the fuzzy stuff and out of sight. It worked great for me.

Hey Graham, I might be interested in the new door panel platforms also. Might be a good candidate for upholstering back to the original look.

[Mike]

Yea, keep us posted on this project. This could be an inexpensive alternative for many people to get new door panels put together.

[graham53]

Here it a rebuilt door panel using the pattern above. Seams folded and welded and a heat gun used to form the comppound curves. It is made out of sintra 1/8" pvc sheets. I will now cover the inside face with second skin and then the vinyl kit i bought.

[graham53]

sorry here is the photo

[plutovitch]

David,

Im in awe!! Perfect solution to an otherwise expensive option of buying new door panels (AUS$300ea.!!).

To form the compound curves you laid the pvc sheet over the door, heated and applied pressure to form the curves?

Great Job!!

[EScanlon]

David;

Did you heat over an actual door in order to get the curves right?

Looks excellent, but as you pointed out those compound curves may be tricky without the "mold" of the actual door.

What about the "cut" lines that your pattern showed?

Was it difficult to close the space, and how did you "weld" those edges together?

Thanks for sharing this.

Enrique