Re: Has anyone made door panels themselves?

Posted by HH56 On 2011/6/7 9:14:48

I have made two sets for postwar cars using 1/8" fiber board--similar to the Masonite some Packards used but smooth on both sides. Thickness results varied -- with fabric, one was thinner--more along the lines of the cardboard door panel material. The other turned out to be a bit thick with all the vinyl material wrapped around the edge -- but worked. Another friend I know used luan plywood which also worked but no idea on how that has held up. Both of mine seem to be holding up OK but was a P.I.A. to cut all the clip holes with a jigsaw. Being a compressed product, not terribly waterproof so if that is a concern, some treatment or added protection on the door itself would be a good idea when using something like that.

A friend in the upholstery business is now using ABS plastic sheets. He gets them from his upholstery wholesaler and says it's the same thickness as the cardboard panels which would put it around .115. Some holes he cuts with a saw, drill or punch and others he melts using some kind of heated tool. I didn't see one of those but he says it's easy, strong, waterproof and he wouldn't do any the old way again unless his customer insisted.