Another 52 interior door panel

[oldman3]

Hey everyone. I'm going to show how I made another door panel. This is based on the new way my son (Mark -Reaper71) and I learned from Erin. It is different and a new learning curve, but not bad. I didn't take a lot of pics because of this, new way, but it should show enough to be able to follow. If there are any question let me know...Jim

Pic #1 This is the panel I built back in May of 2019 for my friend Ed. This panel he wanted installed using screws (his call not mine). The panel had been taken off and on so may times by him and others, that it really looked bad and beyond repair. So here we go...

[oldman3]

This is Ed's door, this is NOT how you cut a door to install power windows (NOT OUR WORK).

[oldman3]

I'm going to show each pic with remarks one at a time, so it's easier to follow.
This is the 20 gauge sheet metal that was formed to door shape. The white 1/8" plastic has been glued to the panel. (Panel was sanded in area where plastic will go, then super glued applied to metal, the spray activator on plastic and held together.

[oldman3]

This is the insert piece with the plastic that will be glued to insert.

[oldman3]

Here I've set the metal insert piece into place. (earlier I had drilled 1/8" holes thru both panels to know where magnets would go.)

[oldman3]

Here the 1/8" plastic has been glued to the metal (super glue,activator) insert piece, then I will trim to the metal.

[oldman3]

Here the magnets have been glued to the main panel (super glue, etc).
(Note: second layer of magnets set in place to transfer to insert panel, this will help to make sure magnets attached to each other later).

[oldman3]

Here I've taped scrap 1/8" plastic pieces to first layer of plastic. (This was done to help in the next step. Later 2" wide pieces of plastic will be glue to lst layer to create the pleated look)

[oldman3]

Magnets had been glued to insert panel and put into place. I put fiberglass filler around the outside edge to create a raise area.

[oldman3]

This is the back of the main panel, you can see the shape in the metal that matches the door. Vinyl has been applied to panel and glued to panel and on the back side. For this part I used vinyl top glue as on the old panel.

[oldman3]

The main panel is mounted to the door with four screws that are in the insert panel area (will be covered later and won't know their there).

[oldman3]

Another view showing magnets that will hold the insert in place.

[oldman3]

Back of insert panel with magnets showing. Notice these are flush to the metal and are glued to the plastic. While the main panel magnets were raised.

[oldman3]

Here the insert panel is in place. This is a snug fit and the magnets hold the two pieces together.

[oldman3]

This is the old arm rest, old material removed, arm modified for different mounting, and covered with vinyl.

[oldman3]

This mount is angle iron that was welded to door during the orginal plans for this panel. Metal and plastic panels were all cut to allow this to stick out as shown. Holes were drilled and taped for 1/4"X20 bolts.

[oldman3]

Not a good pic, but arm rest in place and lined up.

[oldman3]

Pan head 1/4"x20 bolts hold arm rest in place.

[oldman3]

This is filler panel for arm rest (made out of 1/8" plastic and covered with vinyl, magnets will hold it in place.

[oldman3]

Filler panel in place (dropped down into recess in arm and held with magnets).

[oldman3]

Upper part of panel and garnish mouldings in place.

[oldman3]

Lower part of panel with the accent piece to hold panel snug to the door. Power window switch close to arm rest. The accent piece is 1/8"aluminum brushed and clear over top, could be painted black, but Ed liked the aluminum.

That's it troops...Jim

[joedoh]

unbelievable, both what passes for a power window install and for the amazing work on the door panels!

[oldman3]

Originally Posted by joedoh

unbelievable, both what passes for a power window install and for the amazing work on the door panels!

Thanks Russ...Jim

[mongocanfly]

great work Jim...as usual