Build your own door & interior panels

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  • Chrome
    Ph.D in Redneckology
    • Aug 30, 2002
    • 8526

    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:

    Last edited by Chrome; 02-01-2007, 12:39 PM.
    ..,=====,o00o
    //__l_l_,\____\,__
    l_---\_l__l---0
    lllllll0
    _(o)_)__(o)_)--o-)_)___


    1983 Cherokee Chief Laredo W/T 360/auto

    1982 Cherokee Chief W/T 360/4 speed

    I now have an official Muslim name...Ochroma Bin Polishin.

    Click link for pics of restored Full Size Jeeps (on last page)
    http://www.cardomain.com/ride/363842\
  • bigun
    • Feb 10, 2003
    • 20092

    #2
    you had to know this was coming



    charlie
    KB0HXA
    "Crom" 76/75 Cherokee/J20 Hybred,

    Originally posted by Gambler68
    congrats...that's the first post on here I have absolutely no effing clue how to comment on.
    How you behave toward cats here below determines your status in Heaven.
    Robert A. Heinlein
    The birth of CROM is recorded here
    http://www.alaska4x4network.com/showthread.php?t=7778

    Comment

    • Heavy_Metal_Thunder_81
      Cherokee Outlaw
      • Jan 10, 2006
      • 7292

      #3
      Yea! Sounds like youve done this before...
      -Jonny B.
      1979 Cherokee Golden Eagle - UNDER CONSTRUCTION
      7" Alcan springs, BJ's HD shackles - 35x12.5x15 BFG Mud Terrains
      AMC 401 - Pro-Flo 4 EFI
      NV4500/NWF BB/NP205 - Triple Stick'd
      F D44 - 4.10, Eaton E-Locker
      R M23 - 4.10, Detroit Locker

      1979 Cherokee Chief - Parts
      1979 Cherokee Chief - Parts
      1979 Wagoneer - Sold
      1981 Cherokee Chief - Cubed

      Comment

      • Chrome
        Ph.D in Redneckology
        • Aug 30, 2002
        • 8526

        #4
        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.
        ..,=====,o00o
        //__l_l_,\____\,__
        l_---\_l__l---0
        lllllll0
        _(o)_)__(o)_)--o-)_)___


        1983 Cherokee Chief Laredo W/T 360/auto

        1982 Cherokee Chief W/T 360/4 speed

        I now have an official Muslim name...Ochroma Bin Polishin.

        Click link for pics of restored Full Size Jeeps (on last page)
        http://www.cardomain.com/ride/363842\

        Comment

        • Ristow
          • Jan 20, 2006
          • 17292

          #5
          hey,that looks pretty dang diddly-doo-darned good!


          sorry,the ned flanders in me came to the surface for a sec there.
          Originally posted by Hankrod
          Ristows right.................again,


          Originally posted by Fasts79Chief
          ... like the little 'you know what's' that you are.


          Originally posted by Fasts79Chief
          I LOVE how Ristow has stolen my comment about him ... "Quoted" it ... and made himself famous for being an ***hole to people. Hahahahahahahahahha!

          It's like you're unraveling a big cable-knit sweater that someone keeps knitting...and knitting...and knitting...and knitting...

          Comment

          • etjeep
            350 Buick
            • Oct 03, 2003
            • 839

            #6
            Nice job....
            Later.....
            Eric

            ___________
            Eric Terjesen
            '78 Wag
            '03 Silverado 2500 Tow rig

            Comment

            • bigun
              • Feb 10, 2003
              • 20092

              #7
              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
              charlie
              KB0HXA
              "Crom" 76/75 Cherokee/J20 Hybred,

              Originally posted by Gambler68
              congrats...that's the first post on here I have absolutely no effing clue how to comment on.
              How you behave toward cats here below determines your status in Heaven.
              Robert A. Heinlein
              The birth of CROM is recorded here
              http://www.alaska4x4network.com/showthread.php?t=7778

              Comment

              • DAHoyle
                350 Buick
                • Nov 25, 2005
                • 999

                #8
                Yeah, looks ok, but what was wrong with the old ones? JK
                67 M715
                Cummins 4BT/Allison 54/Ford203/Ford205,
                Front 89 HP60/Rear 81 GM D70HD
                Discs all around/ 12 bolt H1 Rims
                Build still very much in progress


                78 Levi edition Honcho 360/T18/D20


                Comment

                • OBX-AUTOMOTIVE
                  GRUMPY
                  • Apr 10, 2001
                  • 6875

                  #9
                  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?

                  Comment

                  • jeepfan93
                    304 AMC
                    • Feb 07, 2006
                    • 2100

                    #10
                    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.
                    Jeeps are Jeeps, keep Jeepin
                    >It's not about the ten hour drive to get the rust bucket jeep, it's about where your your going when it's done
                    87GW 99 Durango 5.2 drivetrain, SOA 35in Falken Wildpeak. MT rims
                    1997 Ram 1500 5.2 33in Falken Rocky Mounts for haulin

                    Comment

                    • Lindel
                      Perfesser of Jeepology
                      • Jun 15, 2000
                      • 9205

                      #11
                      Good write-up Scott, but where can I get sheet fiberglass?
                      Jeep Grounds
                      RRV Homepage
                      Texas Full Size Jeep Association
                      1987 Grand Wagoneer
                      AMC 360/TF727/NP229
                      1999 Wrangler Sport
                      4.0L/AX-15/NV231


                      ?Freedom is never more than one generation away from extinction? by Ronald Reagan.


                      Formerly of DFW/Gun Barrel City, TX - eventually to return...

                      Comment

                      • Heavy_Metal_Thunder_81
                        Cherokee Outlaw
                        • Jan 10, 2006
                        • 7292

                        #12
                        Originally posted by Lindel
                        Good write-up Scott, but where can I get sheet fiberglass?
                        What he said and NICE JOB!!!
                        -Jonny B.
                        1979 Cherokee Golden Eagle - UNDER CONSTRUCTION
                        7" Alcan springs, BJ's HD shackles - 35x12.5x15 BFG Mud Terrains
                        AMC 401 - Pro-Flo 4 EFI
                        NV4500/NWF BB/NP205 - Triple Stick'd
                        F D44 - 4.10, Eaton E-Locker
                        R M23 - 4.10, Detroit Locker

                        1979 Cherokee Chief - Parts
                        1979 Cherokee Chief - Parts
                        1979 Wagoneer - Sold
                        1981 Cherokee Chief - Cubed

                        Comment

                        • gmarblestone
                          327 Rambler
                          • Sep 18, 2005
                          • 512

                          #13
                          Agreed, i will be venturing here soon!
                          1985 Wagoneer
                          1984 Wagoneer ( parts But maybe chop top )
                          1967 Mustang Fastback S-Code
                          1971 Cutlass Convertible

                          http://www.marblestone.org/project_wagoneer.aspx
                          Pictures

                          Comment

                          • janie
                            • Aug 11, 2001
                            • 8270

                            #14
                            Awesome work Cuz!
                            He is your friend, your partner, your defender, your dog. Faithful and true to the last beat of his heart. You owe it to him to be worthy of such devotion.

                            Comment

                            • Bama Burden
                              350 Buick
                              • Jul 28, 2005
                              • 1177

                              #15
                              sha-zayum! any solutions for my POS armrests?

                              Comment

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