How To Build Custom Door Panels

[X-cabsquarebody]

There is a million ways to build door panels. This is one of the easiest ways and they mount like the original panels.

First, I cut the center out of the my old door panels. The outer part of the panel has all the mounting stuff in it, clip holders, and screw holes.

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Cut a piece of 1/4 plywood so it fits in the center of the panel. Attach the Plywood to the plastic. It just need to hold temporary, later it will all get glassed together. Epoxy, or even high temp hot glue will work.

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I drill holes around on the plastic to give the resin some bit and help it hold to the plastic. Stretch a piece of polyester Tee shirt, or fleece over the whole panel. At this point mount the panel to a door. This will help hold the shape as the resin sets. Coat the polyester resin, and let set.

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Sand the edges smooth, and lightly sand the panel, just knock the shape points off. At this point, you have a blank panel.

 

[Old77]

I've been wanting to do this for a long time!!

 

[X-cabsquarebody]

Cut the bucket out of your old panel that goes behind the handle.

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Using the center of the old door panel for a template, cut out a hole for the piece around the handle.

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Measure of the armrest bracket and cut out a hole. This bracket is necessary to mount the armrest frimley to the door.

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Now, figure out what shape you want your arm rest. Cut the base piece of the armrest out of 1/4"plywood, and drill and mount some Tee nuts, or blind nuts, so the armrest can be bolted to the door. Cut out a second piece out of 1/2" plywood for the top part of the armrest. Attach the two together, glue, screws, and or nails,,,etc. Stretch a piece of material over it and coat it in resin.

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[X-cabsquarebody]

Sand the edges smooth, and sand the sharp points off the surface. Cover in padding. I use a 1/8" close cell form. Cover the panel with padding too.

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Wrap in vinyl, leather or cloth etc,,,,

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These are in my own daily driver. I wanted them to be understated and not over power the rest of my truck. There are tons of possibilities. I have power widows with the switch moved to the center console. For manual windows, drill a hole of the regulator stem.

 

[foamypirate]

Nice job! Got any pictures of the finished product on the truck?

 

[rscustomrods]

Wow!!! Great Job! I wish I had your skills. I may take a shot at it based on this thread and see what happens. I have a few extra door panels I can screw up

 

[X-cabsquarebody]

Wow!!! Great Job! I wish I had your skills. I may take a shot at it based on this thread and see what happens. I have a few extra door panels I can screw up

Hell yea! I've been screwing things up for years. But I have had a lot of practice. Making door panels and interior stuff anyway. Lol

 

[Lethermon]

Those ar Saweet!!

 

[DavieL]

Those are some good looking panels. Very good info thanks for the thread.

 

[Stroked]

Wow, you did an awesome job! I guess I'll have to save all those junk door panels I was going to throw away. Lol.


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[Devillusion]

Wow, impressed....and look forward to giving something like that a shot very soon. Nice work!

 

[Mr Clean]

how did you get the leather or what ever you used to form on the door panel and make it look seamless? I'm wanting to do this soon, I really like what you did.

 

[X-cabsquarebody]

how did you get the leather or what ever you used to form on the door panel and make it look seamless? I'm wanting to do this soon, I really like what you did.

It is seamless. On the corners, I warmed the vinyl and work it out to the edge. The trick is, a LITTLE heat, and a little stretch on the vinyl.

 

[Mr Clean]

It is seamless. On the corners, I warmed the vinyl and work it out to the edge. The trick is, a LITTLE heat, and a little stretch on the vinyl.

Cool, what do you warm it with, like a hair dryer? What do you use to secure the vinyl to the door?

 

[X-cabsquarebody]

I use a heat gun,,, but hair dyer is more for giving. Industrial contact cement to glue padding and vinyl. Get a cheep automotive spray gun and spray able contact cement and your local hardware store. FOLLOW THE DIRCTIONS ON THE CONTACT CEMENT!!!

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