How to make door panels

[oldman3]

I told some friends on the site about doing door panels so here it goes. This is how I do interior door panels. There are many ways to build them, but this is how I do it. There is no sewing, all glued and stapled together. I learned most of this from the DVD from Sid Chavers.

All of these pics were taken today, but I had started some of the work last week at Ed's place, where his car is kept. Can't use my shop now, it's full already, so I did most of the primary sizing of panels at Ed's and then brought back to my shop.

[oldman3]

Here was the current door panel on Ed's 1947 F@rd coupe. Not bad, but it wasn't what he wanted. It didn't show enough of the shape he wanted, to heavy with the foam, etc., and had ugly screws holding the panel to door (see pic 1).

But the main problemwas that the door panel and arm rest were so wide that they hit his seat (see pic 2). You would have to SLAM both doors to close them. He has already broken two door windows on the passenger side. So I'm going to slim it up and make a new panel.

[oldman3]

I use 1/8" lauan, some call in sub floor, or you can use 1/8" wood wallpanels. Lauan will bow going with the grain. So if your door has a bow, left to right, or top to bottom, make sure to put the grain that way. I cut the panel close to the size of the door. I then place it on the door and use to small metal screws to hold the panel in place. Trace the outside of the door to the back of the panel. Remove and cut panel to shape. Reinstall the panel with the two screws and check for alignment. This door already had holes from the old panel, so I used a shape awl to transfer the holes to the panel. I then removed panel and used a hole punch to make the holes and installed the door clips. I'll tell size of punch and show clips tomorrow. First pic is how the panel looks and the second shows how panel can bow.

[oldman3]

Now you need to trace the first panel to another sheet of lauan to make a second panel the same size as the first, this pic shows the ruff size. I almost forgot make sure after you cut your lauan, you sand all edges with 80 grit sandpaper, to make it smooth and get rid of the splinters.

[oldman3]

Ed and I had come up with a design at his shop, that was lightly drawn on masking paper, I brought that home and refined it, the used a marker to show shape (see first pic). I then cut that out with a razor blade (see pic 2). I used that template on the second panel to mark with pencil for where panel will be installed.

[oldman3]

I then take the inner template and mark up another piece of lauan (pieces from sheet for first panel), to make a hard template (see pic 1). When cutting out an inside opening I usea saber saw. I drill a couple hoes to start and cut out the design. Go slow and follow the lines and it should work fine. This piece is what came out, but can not be used (see pic 2). After hole is cut I use that piece to make a hard template for the arm rest (see pic 3).

[Advanced Design]

Great tutorial Jim. Thank you for sharing the how to.

[solidaxel]

Yes, thanks for the tips!

[oldman3]

Originally Posted by Advanced Design

Great tutorial Jim. Thank you for sharing the how to.

Originally Posted by solidaxel

Yes, thanks for the tips!

Thanks guys, appreciate you checking out the thread..Jim

[Clarance J]

Thanks oldman3. Its always good to learn something like this. Enjoying the process of what you are doing. Will watch till the end.

Earl

[oldman3]

Originally Posted by Clarance J

Thanks oldman3. Its always good to learn something like this. Enjoying the process of what you are doing. Will watch till the end.

Earl

Thanks Earl, could not work on it yesterday, 6" snow and other health issues, but will be back on it today, with an update...Jim

[aggie91]

Great to see this kind of thread. Thanks for sharing Jim.

LIZ - This is the kind of thread that I would like to see for the Interior Forum I have mentioned....

Sorry to hi-jack this Jim, but fits with something I have asked for here:
http://67-72chevytrucks.com/vboard/s...d.php?t=660687

[Possmguts]

Im in to the finish. I am a carpenter but doing something like this is out of the norm for me.

[oldman3]

Originally Posted by Possmguts

Im in to the finish. I am a carpenter but doing something like this is out of the norm for me.

Thanks, will be giving up update here real soon...Jim

[oldman3]

Well, things were really messed up yesterday. 6" of snow, health problems, so I'm late on the update. I mentioned I would show the punch and clips I use. So I'm going to start there and then continue with the panels.

First pic is the punch I use, it is a 1/4" hollow punch. The clip on the left is the clip I'm currently using Auveco #11406. The clip on the right is better, but it is getting harder to find, and Auveco no longer shows a part number.

Second pic shows how the punch makes a clean hole, or you could use a 1/4" drill bit.

Third pic shows the clip installed.

[oldman3]

Here in the first pic I've put a scrap piece behind the top scrap piece

Second pic shows the gap between the two panels. What I do is mark thru the first panel clip area on to second panel.

Third pic, I then take a cut off wheel (using the edge) and remove approx. 1 layer of lauan to create a little dip in the panel for the head of the clip to lay. 99% of the time when removing a layer it will change color.

Pic 4 now shows how flat the two panel lay.

I'm showing all this now, because as the two panels go together this is how it will look.

[oldman3]

Originally Posted by aggie91

Great to see this kind of thread. Thanks for sharing Jim.

LIZ - This is the kind of thread that I would like to see for the Interior Forum I have mentioned....

Sorry to hi-jack this Jim, but fits with something I have asked for here:
http://67-72chevytrucks.com/vboard/s...d.php?t=660687

Thanks Aggie 91. I posted on your thread and also on the link Liz showed, so I hope it shows up that I would love to have an Interior forum. Karl you didn't hi-jack, it made me aware of what you were trying to do, which is great...Jim

[Advanced Design]

Very clear and easy to follow Jim. I could print this out, take it to the shop and make some door panels...maybe. Probably make some scrap panels first as is part of learning process.
How do you determine where to put the clips? Or how do you transfer the clip location to the door accurately? Thank you!

This should be a sticky in the interior forum.

[oldman3]

Originally Posted by Advanced Design

Very clear and easy to follow Jim. I could print this out, take it to the shop and make some door panels...maybe. Probably make some scrap panels first as is part of learning process.
How do you determine where to put the clips? Or how do you transfer the clip location to the door accurately? Thank you!

This should be a sticky in the interior forum.

Thanks Doug,
Believe me I've made plenty of scrap panels. This job the door already had holes I just lined up the awl and pushed thru the panel. If your starting from scratch, put the panel on the door and drill holes thru the panel into the door. Depending on size of door about 4 holes on the sides and 5 along the bottom....Jim

[jjzepplin]

Subbed!

[oldman3]

Well time for todays update. Not as much done as I wanted, but still progress.

First pic is the pass. panel that will be covered today.

Second pic is the 1/8" closed cell foam (also called sculpting foam, or landau top foam). I cut out some of the foam to it won't stick in that area.

Third pic you can see the glue has been sprayed on the foam and the panel.

[oldman3]

First pic, I thought I would show this glue for those that don't have or don't want to buy the equipment I'm using. This stuff works great and can be picked up at your local auto paint supply.

Second pic, here I'm installing the foam. I start at the top and work my way down, moving left to right to keep it smooth.

Third pic, here the foam is in place. I use a bondo spreader to help lay the foam down.

[oldman3]

Mark needed to spray some primer, so I left the shop for a couple hours.
First pic shows the foam in place and excess foam has been removed. I use a razor blade to cut the foam.

I messed up and didn't take any pics, but after the foam is on, you are ready to cover with material. I roll out the material, place the panel on the material. I leave about 1-1/2" extra around the panel, mark it and then cut out the material. After material is cut to size I place the panel right side up and material right side up, to check and make sure everything is OK. I then pull the material over itself about half way down the panel, so the back side is up. I then spray glue on the top half of panel and the back side half of the material. Let this tack up, then I use the spreader and start up the under side of the material to attach to the foam. Once that's down you can go back to the design area, use the spreader to puch the material down and along the design edge.

Second pic shows this done, and I also put in a few staples along the edge.

Now do the same thing to the second half of material and foam to finish the bottom of panel. You would also use the spreader to push the material down for the two design lines.

Thrid pic shows this done.

Forth pic shows the entire panel and material.

If what I explained isn't clear, let me now and on the second panel, I will take more pics.

[oldman3]

First pic, I also forgot to mention that I use 4 or 5 pieces of 2"X2" blocks under the panel to keep the clips from touching the work area, so you can work on a smooth surface.

Second pic, I've turned the panel over and glued the material to the back side.

Thrid pic, I've stapled down the material to the panel.

Forth pic, For those that don't have an air stapler, this hand unit works fine and uses the same staples, this one is made by Craftsman.

[oldman3]

Originally Posted by oldman3

I messed up and didn't take any pics, but after the foam is on, you are ready to cover with material. After material is cut to size I place the panel right side up and material right side up, to check and make sure everything is OK. I then pull the material over itself about half way down the panel, so the back side is up. I then spray glue on the top half of panel and the back side half of the material. Let this tack up, then I use the spreader and start up the under side of the material to attach to the foam. Once that's down you can go back to the design area, use the spreader to push the material down and along the design edge.

Now do the same thing to the second half of material and foam to finish the bottom of panel. You would also use the spreader to push the material down for the two design lines.

This is what I posted in post #33, while I was working on the drivers panel today I took pics to show what I was talking about.