Full Door Panel Question

[LuckyJoe]

While doing the mock-up for the door panel I noticed that the very top part has quite a large space to fill between the added panel and existing removable top part. This gap is created because of the design on the top removable panel. I'm thinking that I may have to leave the removable panel off to close the gap. Has anyone left it off or just cut out the raised area? Any suggestions would be appreciated.

Thanks, Joe,

[Highsider]

Nice blue.

[Russell Ashley]

The felts at the lower window opening don't seem to keep much water out. If I were doing full panels like you are doing I would leave off the original panels that have the raised ridges, but I would use a sheet of plastic like some newer cars have to deflect any water away from your new panels. Hang the plastic so that it directs the water into the door.

[OrrieG]

You will need to keep the part that wraps around the door strike, and maybe a piece on the hinge jamb side as a filler too.

[LuckyJoe]

Russell, I'll will actually be using a water proof product I picked up at a local Signarama store. The Lowes hard board is just for mock-up since it's cheap and I most always screw-up a time or two. OrrieG, Yes, I thought about cutting down the steel panel but might also loose too much overall support for the arm rests. The situation may resolve it'self when use the Signarama product since it's more flexible. In any case, Russell and OrrieG I do really appreciate your input. Highsider, glad you like the color, Thanks.

Joe,

[_Ogre]

i left the panel in to cover the gap and fill the area around the latch.



the base for my door panel is 1/4'' plywood with a second layer of plywood cut out to match the raised bead on the oem door panel.
i waterproofed the plywood with fiberglass resin.



i cut the heck out of my door to install 07 dodge durango power windows


built up the door panel to fit my interior, hide door speakers and make a usable arm rest


fiberglassed the framework


stretched and glued vinyl over the panel


carpeted panel and upholstered arm rest

[oldman3]

ogre, nice job on the panel, and lots of pics with details, way to go bud...Jim

[LuckyJoe]

Ogre, that is a lot of work and turned out nice. Must have door poppers and electric windows. I may be able to add some sort of filler strip on the back side of the panel to fill the gap. Thanks for the pics.

Joe,

[Daze57]

good lookin panals !!!

[4DSEVEN]

Nicely done Ogre.

[Dan in Pasadena]

Ogre, now THAT took more fabrication chops! Well done.

Why the Durango power windows instead of an aftermarket setup? Strictly cost?

[_Ogre]

Originally Posted by Dan in Pasadena

Strictly cost?

yes. as in free.

plus i just have this thing about making stuff myself.
i won't build a motor, nor a trans; been there, done that.
but i have no qualms about putting 50 hrs into door panels

and thanks. to all
giving luckyjoe things to ponder