Ok, I bought a new vinyl panel for the inside of the hatch. It didn't come with any holes in it. The old one was attached via those little plastic pins that are used to attach all the plastic panels. It also had some sort of black sealer around the inside edge, probably to seal out exhaust gas.

I like the look without the plastic pins, but that leaves me with using glue, which I'm concerned wouldn't hold. Has anyone had any luck using just glue? If so, what glue did you use?

If I have to drill holes in this panel, does anyone have any tips on how to do it without messing up the vinyl? I'm thinking just put a piece of tape over it and drill.

The attached picture shows the old vs new panel.

Matt

Saltillo tile! Very nice.

Here's what you do:

(1) Use the old panel as a template to mark your hole positions. Use a sharpie and carefully place a small dot where each hole needs to be.

(2) Drill a hole of the correct size through a wooden block. 3/4" material would be great.

(3) Sandwich the new panel between the drilled block and another block, with the sharpie mark centered at the bottom of the hole. Clamp firmly together with a couple of C-clamps.

(4) Insert your drill through the hole, and drill through the panel. The wooden block will keep the vinyl taught and flat and will prevent it from wrapping around the bit.

(5) Repeat, repeat, repeat.

FAIW, the previous owner of my car replaced the OEM push pin thingies with screws and finish washers. The finish washers he used rusted slightly, as did the screws. I replaced with stainless oval-head screws and stainless finish washers. It looks fine. The screw heads and washers can always be painted with a good epoxy paint to match the vinyl. I've done that on kitchen cabinet hardware and have found the finish to be quite durable.

I'm going to ask a dumb question to see if it can spark a good idea... Is it possible to drill holes in the backing plate and use clips like the ones that hold on the doglegs, or the door panels? I think I've seen those clips in all different sizes. Just an idea.

I'm going to ask a dumb question to see if it can spark a good idea... Is it possible to drill holes in the backing plate and use clips like the ones that hold on the doglegs, or the door panels? I think I've seen those clips in all different sizes. Just an idea.

I thought about that, but I'm afraid the bit would snag the viynl. The vinyl is stapled on the backing plate, so I could remove it, drill the holes and restaple, but it'd be a real challenge to restaple it.

The wooden jig is a good idea, but what a pain. I can't believe this thing was shipped without the holes already drilled. It must be because some people don't want holes in it.

Might try a paper hole punch. I've used that tool all around the shop for making holes in gaskets and innertube to make non-existant gaskets.

Bonzi Lon

Might try a paper hole punch. I've used that tool all around the shop for making holes in gaskets and innertube to make non-existant gaskets.

Bonzi Lon

I think a leather punch would be the best tool for this.

Here's several http://search.harborfreight.com/cpisearch/web/search.do?keyword=leather+punch&Submit=Go

or better yet. Unwrap it, mark your holes, drill then out to 1/4" then make a channel 1/4" away to a bigger 1/2" hole to allow the head thru then slide into place. Rewrap it and drill all your sheet metal holes to 1/4" or 5/16" to allow the new clips to lock into place in the sheet metal. You won't see the clips and it'll hold great.

Dave

Buy 'em here... http://www.autobodysupplies.com/Interior%20Door%20Panel%20Clips%20Page%201%20.htm

Edited October 27, 200915 yr by Zs-ondabrain