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-   -   Build your own door & interior panels (http://www.ifsja.org/forums/vb/showthread.php?t=63456)

Chrome 01-31-2007 10:24 PM

Build your own door & interior panels
 
If you want to replace those worn or rotted interior door panels and rear quarter interior panels then here's a cheap way to.....Git-R-Done. You will need a sheet of 1/8" thick fiberglass, like the kind used to underpin mobile homes and subframe houses, a hot glue gun, a pack of hot glue sticks, and the material you entend to use to cover the panel with (preferably marine grade vinyl). Tools that are required are a jigsaw with a fine cut blade, a drill with assorted bits, and a black Sharpie.

Remove your old panel and remove any pieces that will keep it from laying flat on the fiberglass board. Now line up any square edges with the straight edge of the FG board then trace a outline of the old panel onto the FG board. Carefully cut out the pattern and then test fit it to the door/quarter that it will be attached to. Keep in mind the trim piece at the top of the door that the factory panel slides under and allow enough excess to fit back under it. Make sure not to leave any sharp edges on the FG board because this will cause premature splitting of the vinyl.

Once you have the desired fit you will need to go back and mark any holes that need to be cut into the FG board like speakers, door handle, window crank, power switches, arm rest, ash tray, etc. BE SURE TO MAKE THE HOLES THAT THE DOOR CLIPS FASTEN THRU TO HOLD THE PANEL ON. YOU CAN USE THE PLASTIC TYPE LIKE USED ON NEWER MODEL VEHICLES. THESE CAN BE FOUND AT MOST PARTS STORES. If you are adding something that was not orginally in the panel like speakers make sure the location you pick on the board will match the body of the vehicle and not be in the way of a lowered door glass or wheel well.

Now that you have your pattern finished double check to make sure it is clean of FG shavings or any type of trash that will show up on the finished product. Also, if the FG board has one side that is smoother than the other then it's best to use the smoothest side.

Take the material you plan to cover it with and stretch it out over the board. You will need to leave a 1 1/2 inch excess around the outside edge this will be used to glue the material to the board. Once you have the material trimmed flip the material up side down and place the board down on top. MAKE SURE YOU HAVE THE RIGHT SIDE OF THE BOARD FACING DOWN ON THE MATERIAL OTHERWISE YOU JUST MADE A SPARE. Take the hot glue gun and make a bead across the top edge of the board then pull the material over and press it down. This may take a few minutes of rubbing to get the material to stick but once the glue cools it will stick. Now gently pull out any wrinkles in the material and place a bead of hot glue along the bottom edge and lay the material over it making sure you do not leave wrinkles in the material. You can gently move the material if needed just don't try to give it a hard pull. Once the bottom has cooled double check the covered side to make sure everything is looking smooth. Now do the sides the same way. On the rounded edges you will need to make relief cuts on the back side so that the vinyl will not crease on the top side. This can be done by cutting a straight line from the outside edge of the vinyl inward towards the FG board edge and stopping at least a 1/4 inch from the edge where it wraps over to the top side.

Once the material is in place go back and take a new razor blade and cut out the holes that you made in the FG board. Be sure to put a small amount of hot glue under the edge of the cuts to help hold them flat. THERE IS NO NEED TO PUT ADHESIVE SPRAY ON THE COVERED SIDE OF THE BOARD. THE GLUED EDGES WILL HOLD THE MATERIAL IN PLACE.

Now place the newly covered panel on stand back and admire a job well done!

BEFORE:







AFTER:


bigun 01-31-2007 10:27 PM

you had to know this was coming



:worthless:

Heavy_Metal_Thunder_81 01-31-2007 10:44 PM

Yea! Sounds like youve done this before...

Chrome 01-31-2007 10:50 PM

LOL After all that typing I wanted to make sure I had it posted before I started transfering pics. The way my luck goes I would hit the wrong button and lose everything then it would be a trip to the doc for a case of Carpel Tunnel.

Ristow 01-31-2007 11:34 PM

hey,that looks pretty dang diddly-doo-darned good!


sorry,the ned flanders in me came to the surface for a sec there.

etjeep 01-31-2007 11:41 PM

Nice job....

bigun 01-31-2007 11:54 PM

Quote:

Originally Posted by The Chrome-a-nator
LOL After all that typing I wanted to make sure I had it posted before I started transfering pics. The way my luck goes I would hit the wrong button and lose everything then it would be a trip to the doc for a case of Carpel Tunnel.

OH man I have been there LOL or switch sites to get corroborating evidence to prove your point and forget that what ever you typed won't be there when you get back

DAHoyle 02-01-2007 06:13 AM

Yeah, looks ok, but what was wrong with the old ones? JK

OBX-AUTOMOTIVE 02-01-2007 06:30 AM

YOU DO NICE WORK...I REMEMBER THAT POST FROM BEFORE...LIKE TO WORK WITH YOUR HANDS?...WOULD YOU LIKE TO BUY A FLOOR/PAN EMPIRE? :)

jeepfan93 02-01-2007 06:30 AM

THERE IS NO NEED TO PUT ADHESIVE SPRAY ON THE COVERED SIDE OF THE BOARD. THE GLUED EDGES WILL HOLD THE MATERIAL IN PLACE

Hey Scott, only thing I would add is that you may want to use spray adhesive unless thos chrome srtip are going thru and also holding it down. When I used to work in the boat industry, we made our own panels, and lemme tellyou, when that sun warms up the vinyl, it will unloosen, (melt) the hot glue causing things to start popping off.
Looks great though, I'm gonna make panels like that for my 715 soon.

Lindel 02-01-2007 07:14 AM

Good write-up Scott, but where can I get sheet fiberglass?

Heavy_Metal_Thunder_81 02-01-2007 07:18 AM

Quote:

Originally Posted by Lindel
Good write-up Scott, but where can I get sheet fiberglass?


What he said and NICE JOB!!!

gmarblestone 02-01-2007 07:48 AM

Agreed, i will be venturing here soon!

janie 02-01-2007 08:09 AM

Awesome work Cuz!:thumbsup: :thumbsup: :thumbsup:

Bama Burden 02-01-2007 08:54 AM

sha-zayum! any solutions for my POS armrests?

goldhammer 02-01-2007 12:28 PM

Check with the bigger building supply places for the panels. They are available for bathroom walls in 4x8 sheets.

chrisnsarah 02-01-2007 12:34 PM

Quote:

Originally Posted by goldhammer
Check with the bigger building supply places for the panels. They are available for bathroom walls in 4x8 sheets.


Are you referring to FRP (fiberglass reinforced panel)? It pretty good stuff and I see where it would work. There is also a polypropylene sheet available that is practically indestructible, but I don't think the big box stores will have it.

67Wagoneer 02-01-2007 12:39 PM

Looks awesome! :thumbsup:

The fabric on my panels is still in good shape, but the boards are warping.

Thanks for the tip! :D

goldhammer 02-01-2007 12:51 PM

I'm pretty sure it is the FRP stuff. Been about 15 years since I was in the floorcovering business and saw it at a show and in our catalogs. If you go to a major store restroom you will probably see it on the walls. Usually a pebble finish, but the back side is smooth IIRC

Chrome 02-01-2007 02:19 PM

Quote:

Originally Posted by goldhammer
I'm pretty sure it is the FRP stuff. Been about 15 years since I was in the floorcovering business and saw it at a show and in our catalogs. If you go to a major store restroom you will probably see it on the walls. Usually a pebble finish, but the back side is smooth IIRC


That's it. Some of the supply stores in my area call it canidate sign board since everyone running for office like making signs out of it.

Chrome 02-01-2007 02:34 PM

Quote:

Originally Posted by jeepfan93
THERE IS NO NEED TO PUT ADHESIVE SPRAY ON THE COVERED SIDE OF THE BOARD. THE GLUED EDGES WILL HOLD THE MATERIAL IN PLACE

Hey Scott, only thing I would add is that you may want to use spray adhesive unless thos chrome srtip are going thru and also holding it down. When I used to work in the boat industry, we made our own panels, and lemme tellyou, when that sun warms up the vinyl, it will unloosen, (melt) the hot glue causing things to start popping off.
Looks great though, I'm gonna make panels like that for my 715 soon.


The strips have tabs that go thru the board but are for looks only. I know Jeep put these on late 70 model trucks and had a wood grain strip on later model Wags but I have seen some without either. The reason I don't reccommend spray adhesive is because it will cause a blistering effect under the vinyl if you get to much. Several years ago a friend of mine asked me to help build a set of rear panels for his K-5 Blazer. He did the spray adhesive and completely ruined the material on the first one. When the spray starts drying the chemicals evaporating from it caused huge blisters all over the material. Luckly we went to lunch after building the first so we did the hot glue on the second board and never had a problem with it.

I'm sure someone with a lot of upholstery experience knows how much to use but for the average joe that's trying to save a few bucks will be better off with hot glue. The worst that could happen is squirting out too much glue and getting your finger tips a hot wax treatment. :thumbsup:

BigRedChief 02-01-2007 02:46 PM

I think yours were my inspiration. I used masonite and spray adhesive though. The other side looks better, but I haven't taken a pic yet.


Subconscious 02-01-2007 02:53 PM

Looks good!

Chrome 02-01-2007 03:02 PM

Looks awesome Big Red and you used CHROME screws...if I ever get out your way I'm buying you a beer!! :D

El Jefe 02-02-2007 09:57 AM

i like that, think i'll do the same since i need door panels.

its a dang shame you people dont live closer to me, cause you see, i'm a shear operator at a trailer plant that makes reefers. i cut 1/16 FRP, 1/8 FRP, and 1/4 FRP. i can cut it to the size i need, then 9 times outta 10, i can get it for free.

JeepBountyHunter 02-02-2007 10:11 AM

Big thumbs up on that one. Also, when I do mine, I have a sorta tribal - south western weave, heavy uphoulstery insert I'm gonna add to mine...
I'd say I'd post pic's when done, but it's a long ways off..
Good job Scott!

El Jefe 02-02-2007 10:27 AM

i was actually thinking of using some 1/8 inch aluminum and covering it, never thought of the fiberglass idea.

Bob Davis '80 Chero 02-02-2007 11:25 AM

Quote:

Originally Posted by Lindel
Good write-up Scott, but where can I get sheet fiberglass?


Nice job from me as well. I used plastic board, the kind used for signs. Its sort of like corrogated cardboard. Cheap, easily cut and stiff; and no fiberglass itching!


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