Re: Has anyone made door panels themselves?

Posted by Rusty O\'Toole On 2011/6/8 14:54:47

There should be an upholstery supply store in your area. They sell big sheets of black cardboard material for this purpose. You can cut out your own door panels and staple the upholstery onto them.

The reason your panels are warped is, there is no vapor barrier in the doors. Cars come with a plastic vapor barrier for a reason, rain water always runs down the glass into the door and warps the panel. You have to make sure the drain holes in the bottom of the door are open and there is a sheet of plastic under the door panel, sealed to the door with caulking.

Another good tip. Don't use the stock metal clips, use Velcro. This holds the panel in place perfectly, makes it easy to remove without damage, and you can move the panel around a little for perfect fit.

The corrugated plastic panels make excellent door panels too. You can buy the material at building supply stores. It's the stuff they use for signs.