How to make door panels

[oldman3]

First pic, I've trimmed off the excess material close to the staples.
Second pic, I've trimmed the material, applied glue, waiting to tack up.
Third pic, here I've pulled material in place, and then stapled and trimmed.
Forth pic, trimmed and glued the large end and waiting to tack up.
Fifth pic, here everything is glued down, stapled and trimmed.

[oldman3]

I'm going to take a break now, to watch Street Outlaws and the Fat boys, will return later and finish up todays work...Jim

[oldman3]

Late, but let me finish this up.
First pic, picture isn't to clear, but wanted to show how you need to keep these corners as smooth as possible, and no bulk, so it sets in the panel flat.
Second pic, with everything we did earlier on checking the size (see post #42), this panel should fit inside the main panel. Looks good here.
Third pic, now I take the old template, lay in place and outline the back of panel.
Forth pic, here you can see the outline.
Fifth pic, Now spray the back side of design panel and the wood area of the main panel, and let it tack up.

[oldman3]

First pic, Now put the panel in the opening and attach to main panel, keep some weight on the panel until your sure the two are glued together tight. You should be able try to move it, but it shouldn't.

Don't forget to change from 1/8" staples back to the 1/4" staples

Second pic, Now flip the panel over, put some weight on the back of the panel as you staple the back around the outline.
Third pic, same at the other end.
Forth pic, I check to make sure the panel was secure, I pulled on it a little, and nothing moved. Here I've taken the armrest template and screwed in place to help hold down a little.
Fifth pic, here I've glued the two strips to the material .

This is where I quit for the night, will start again tomorrow, till then...Jim

[Advanced Design]

That looks really good Jim. Any idea on how many hours you have invested so far?

[oldman3]

Originally Posted by Indian113

Thanks Jim, I really like the way you take your time to teach us old dogs some New Tricks

Ray, I have to apologize for not seeing your post, it was in between my posting an update. I always like to show anyone, anything I know, not the best but fair work...Jim

[oldman3]

Originally Posted by Advanced Design

That looks really good Jim. Any idea on how many hours you have invested so far?

Thanks Doug, I would guess about 20 to 25 hours over about 5 days. Not being real fast and taking time for pic, etc....Jim

[oldman3]

My day as been for sh!t all day, and now the system is packed, tried to upload a pic and was only 40% in 5 mins. Will try later or tomorrow, sorry...Jim

[oldman3]

Let's try this again.

First pic, applied glue to the curved edge of strip. You can see how I've cut "V's" into the end to help it lay flat. You will have to check this dry and figure how you want to do yours.
2nd pic, here it's glued and stapled down (1/8" staples).
3rd pic, the entire strip is glued down and only a couple staples to hold in place.

[oldman3]

Sorry I didn't take a pic of me placing the strip on the main panel. But it is the same as the large piece. Anyhow apply glue to the back side of strip, apply glue to the strip opening on the main panel. Apply pressure and hold in place till it's dry. Now flip the panel over.

First pic, while appling pressure where the strip is, staple along the line for the strip. Make sure to switch back to 1/4" staples.
second pic, with the enod of the material on the strip, if we just fold it over it would be bulky.
third pic, here I've cut down the material, now take a small blunt end and force the material into the little slot that were cut yesterday.
forth pic. here it is glued and stapled in place, and no big bulk.

[oldman3]

First pic, this is a side shot of the panel showing the two strips and how flat the panel is on the back side.
second pic, another shot, and here you can see how the design panels are raised just a little over the main panel.
third pic again showing the difference in panels.

[oldman3]

I'm showing the panel all by itself here. I still need to build the armrest, but I wanted to address a few items:

1. If a person wanted to do a two tone, or two different materials, you can see how easy it would be to have the design panels whatever you wanted.

2. If you wanted a more traditional look you could see pleats in you center design.

3. You could also add carpet to the bottom if you wanted.

Well, that's is for Tuesday. Wednesday (today) I worked on my pickup, hopefully tomorrow I can do some more panel work...Jim

[Advanced Design]

Jim, that looks really good! Again, thank you for sharing your knowledge in a simple to follow step by step process.
Doug

[oldman3]

Originally Posted by Advanced Design

Jim, that looks really good! Again, thank you for sharing your knowledge in a simple to follow step by step process.
Doug

Thank you Doug, appreciate you checking in out...Jim

[Clarance J]

Jim. Thanks for the lessons on here. I think most of us here can stretch and staple material on the door panels but its the little tips and tricks that turn that door panel into a professional looking piece. Very nice. I know I have learned a few things that I will use on another project. Thanks again for taking the time to show us.

Earl

[Indian113]

It's coming together Nice

[oldman3]

Originally Posted by Clarance J

Jim. Thanks for the lessons on here. I think most of us here can stretch and staple material on the door panels but its the little tips and tricks that turn that door panel into a professional looking piece. Very nice. I know I have learned a few things that I will use on another project. Thanks again for taking the time to show us.

Earl

Your very welcome, and thanks for the kind words. Still have some more to do, so I will post as I get more done...Jim

[oldman3]

Originally Posted by Indian113

It's coming together Nice

Thanks Ray, appreciate it...Jim

[Possmguts]

looks really nice OldMan... I think I will tackle something like this in black and gray. Ill pic some pick when I get to that point. Thanks for showing just how easy it can be.

[oldman3]

Originally Posted by Possmguts

looks really nice OldMan... I think I will tackle something like this in black and gray. Ill pic some pick when I get to that point. Thanks for showing just how easy it can be.

Thank you, glad to see someone wanted to try this...Jim

[Indian113]

I think I'll use some of the lessons and modify to change for my style. Like anything else I've learned on this site I can use bits and pieces of different projects to suit my needs. The nice thing about your lessons you tell us why you do things to make it turn out the way you want. I had a auto shop teacher in High School that taught the same way. I learned more from him than he thought he taught me.

[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.

[oldman3]

Here are the pics.
first pic. here i"ve outlined the material I want to remove.
second pic. material removed and ruler in place to hold material down.
third pic. material pulled half way down, glue has been sprayed and setting up.
forth pic. here I'm about half way going back up with the material.
fifth pic, top half done, now the bottom half, sprayed with glue and ready to start attaching.

[oldman3]

Originally Posted by Indian113

I think I'll use some of the lessons and modify to change for my style. Like anything else I've learned on this site I can use bits and pieces of different projects to suit my needs. The nice thing about your lessons you tell us why you do things to make it turn out the way you want. I had a auto shop teacher in High School that taught the same way. I learned more from him than he thought he taught me.

Thanks Ray, I don't know if I'm anywhere near as good as you teacher, but if you take anything from what I'v shown and use it, then I feel good...Jim

[oldman3]

Ok, my last update was Wednesday, worked on my pickup Thursday installing my seat. Finally got back to the shop today, work about 45 minutes to make the above pics. Have friends stop by, so nothing done till around 3:00pm, so heres what I have to show today.

First pic, glued and stapled the material to back of the panel.

Second pic, Glued material to design panel, and here is the back side, all glued and stapled.

Third pic, Front of design panel, ready to go on the drivers panel.

So not much done today, will see how things go tomorrow...Jim