How to make door panels

[oldman3]

Back in the shop for a little while today.
First pic, these are the strips for the drivers side panel.
Second pic, glued, stapled and ready to install.
Third pic, Drivers side panel complete as of now.

[oldman3]

Started working on the armrest. I used 1"X6" boards to make the pieces. I used the templates on the door panel to trace the shape.

First pic, here are the three piece that will be used to make up the armrest. It will be 2-1/4" thick in the center and taper as per my design.

Second pic, bottom view.

Third pic, Starting to cut some shape into the design (top view)

Forth pic, same thing but front view.

Have a lot of work to do to these armrest. So as I get something worthwile to show I will post it up. I'm also starting on the new kick panels to match up to the door panel, so more to come...Jim

[karrlogs]

Keeping tabs on this thread for future reference. Also, thank you for sharing it step by step.

[oldman3]

Originally Posted by karrlogs

Keeping tabs on this thread for future reference. Also, thank you for sharing it step by step.

Thanks, for checking in out...Jim

[oldman3]

Hey guys, things haven't been going the way I want for a few days now. Haven't worked on anything for the last three days, so I thought I might as well post up what I had gotton done until then.

Pic 1 Here I've cut the edge on a 45 degree with the saber saw.

Pic 2 Same thing just the bottom side, it doesn't show up to well.

Pic 3 Here I've cut the opening for the pull ( metal piece from old panel will go here).

[oldman3]

Pic 1 I've installed "T" nut into the base wood, which allows me to install machine screws from the back side to hold the armrest to the panel.

Pic 2 Screws at back of panel.

[oldman3]

Pic 1 Now I've glued and screwed 2nd board to the top board.

Pic 2 Here I've glued and screwed base board to the other two.

Pic 3 Drivers arm rest attached to panel and the passenger arm rest I've started to sand and get in shape.

Pic 4 Just another view.

That's it for now, hope to get back soon to working on kick panels and finish up the arm rest...Jim

[oldman3]

Just wanted to let you guys know I've haven't been doing much on this panel work, due to back problems. Done a little, but nothing worth pics showing. Hope I might be able to do some more soon, so just hang on for awhile...Jim

[jjzepplin]

Get well soon!

[oldman3]

Originally Posted by jjzepplin

Get well soon!

Thanks....Jim

[MP&C]

Jim, nicely detailed how-to, thanks for sharing the details! Now take care of yourself!

[Possmguts]

Jim, We'll be here when you get back... now just worry about taking care of yourself.

[Indian113]

Jim, take care of yourself. Don't mess with back pain to long.

[oldman3]

Originally Posted by MP&C

Jim, nicely detailed how-to, thanks for sharing the details! Now take care of yourself!

Originally Posted by Possmguts

Jim, We'll be here when you get back... now just worry about taking care of yourself.

Originally Posted by Indian113

Jim, take care of yourself. Don't mess with back pain to long.

Thanks guys, I'm waiting on the back doc now, hopefully something will happen soon...Jim

[solidaxel]

That over the hill, down the hill ride, I have noticed is much faster after 65 !!
Easy does it !

[oldman3]

Been taking it easy, my last post was 3/17, these next 4 pics were done on 3/27 nothing special just putting the passenger kick panel together.

[oldman3]

Pic 1 From 3/27 till 4/2 (after Easter) I felt well enough to get out in the shop for a little each day and finished sanding the arm rest into the shape I wanted.

Pic 2 Also on 4/2 I found out the door wasn't closing right and had an issue with the panel and body down near carpet area, so I pulled the panel.

[oldman3]

I'm getting pics wrong and they have dates so. It was a couple days before I could get back to the shop. I want to say that, NO matter how you plan, sometimes things don't work out. So you have to fix it. In my case since I'm working with leather it's easy to take apart and repair.

Pic 1 back of panel, need to remove the staples and pull back the leather

Pic 2 Leather pulled back and then I had to separate the foam from lunan panel.

Pic 3 Then I had to bevel the area down to the corner to get clearance that I needed for panel to clear the body.

[oldman3]

Pic 1 Here I'm putting the panel back together.

Pic 2 all glued and stapled back.

[oldman3]

I was also having issues with clearance on the drivers side panel on the bottom of the panel coming against the carpet hold down piece, so I took the panel apart and beveled that also. Here's two pics showing me taking in apart, no pics showing back together, but it is.

[Possmguts]

Glad to see you're back at it... dont over do it. Those arm rests look nice, cant wait to see how you go about covering them.

[Advanced Design]

Didn't look like much needed to be removed Jim. Were you able to test fit before securing the panel back together? Great detail!

[oldman3]

Again it was a couple days until I could work on the panels again. After further checking it wasn't the panel that was the problem, but how the first interior guy had installed the carpet hold down piece.

Pic 1 shows that the piece was almost a 1/4" out past the body part.

Pic 2 so I removed the screws, moved it inboard, redrilled, etc.

Pic 3 shows the piece installed flush with the body.

[oldman3]

Then after this was done. I still had issues with both the doors not closing right, and hard to open (electric poppers). This was his problem with the old panels, so I had NOT corrected anything. So back to the drawing board to find the problem. After a lot of checking I finally found the problem. This is a 47 Ford coupe and from the factory for some reason there is this metal piece of the body in only this one area on the "B" pillar area (or rear of door jam).

Pic 1 I took this pic yesterday, but found it back a few days ago. This piece is 90 degrees to the jam. The distance from this piece to edge of the door latch is approx 2-1/4". With the thickness of the panel, the distance from panel to the lock pin is approx. 2-1/2", so the door didn't have enough room. I was trying to put approx 3/8" panel in a 1/4" space. So that meant I had to change the panel AGAIN.

[oldman3]

Pic 1 This kick out is what was hitting the metal piece, and will have to be removed.

Pic 2 removed and installed back on the car.

Pic 3 Kick out on passenger panel

Pic 4 Here it's been removed and ready to be glued and stapled back together.

Pic 5 Installed back on the car. Door closes real easy and the poppers work the first time.