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> Door Panel Cores.. thinking aloud, Alternatives to Pressboard?
Rusty
post Oct 11 2004, 07:02 AM
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Has anyone tried an alternative to pressboard for the cores to their door panels?

I've seen panels that are curved at the bottom from moisture or being recovered too tightly. It seems to only get worse as it ages.

So, any ideas for a replacement material? Some kind of plastic, maybe?

-Rusty (IMG:style_emoticons/default/smoke.gif)
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Bruce Allert
post Oct 11 2004, 07:06 AM
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Someone posted a few weeks ago about using carbon fiber for their door panel and said it was working very good.

....b
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morgan
post Oct 11 2004, 07:07 AM
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masonnite That could work.
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TheCabinetmaker
post Oct 11 2004, 07:13 AM
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Masonite will warp like crazy when wet, unless you use the tempered variety.
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BIGKAT_83
post Oct 11 2004, 07:22 AM
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Made these out of 1/8" wall panel board and was able to sew thru the board with the sewing machine. Made both panels from scratch in about a half of day total cost less than $20.

Bob


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TimT
post Oct 11 2004, 07:23 AM
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You can get 1/8" PVC sheet from McMaster-Carr, its about $50 for a 4X8 sheet. Its easy to cut, and shape. Also very weatherproof. We use it for splitters on the racecars, but we have made dashes from it as well.

I think it would be a great material for door panels
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Bruce Allert
post Oct 11 2004, 07:25 AM
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Here's the one I remembered:

QUOTE
synthesisdv Posted: Sep 22 2004, 02:05 PM  



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I made my door panel from CF, my first CF project. Was easy cuz its just a flat piece. I have other composite projects planned but right now I need to get this lump running again. I like mixing modern materials and technology with old cars or buildings, the juxtapostion brings out the best in both.

Not sure why you care what some others may think of your ideas. Just carry your own flag and I'm sure the likeminded members will find you.  

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Qarl
post Oct 11 2004, 08:51 AM
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There is a synthetic board that custom photo places use... it's called Sintra board... pvc based.

It is also thermoplastic, so it is heat formable.
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boxstr
post Oct 11 2004, 10:00 AM
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Hot rod show in Sacramento that I went to had a ton of vendors, one of them was a hot rod interior supplier, door panels and supplys.
They were using abs plastic for door panels. No water absorbtion, no warpage,cuts easily, you can even heat it with a blow torch(there recomendation) for bending our molding, you spray on glue to hold your material for covering.
You secure it to the doors with a 3m product that is a heavy duty velcro. Glue one strip to the door panel and another to the door. Easy on and off.
It is used to make numerous other car goodies, consoles,speaker holders,arm rests.
CCLINPLASTICISOURFRIEND
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Joe Bob
post Oct 11 2004, 10:06 AM
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I used Lexan. Easy to cut with my sheet metal nibbler, doesn't crack and I had enough left over for a Speedster type windshield for Franky...
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morph
post Oct 11 2004, 10:13 AM
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we are using fiber glass for our door panel.
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Rusty
post Oct 11 2004, 10:20 AM
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QUOTE(boxstr @ Oct 11 2004, 11:00 AM)
Hot rod show in Sacramento that I went to had a ton of vendors, one of them was a hot rod interior supplier, door panels and supplys.
They were using abs plastic for door panels. No water absorbtion, no warpage,cuts easily, you can even heat it with a blow torch(there recomendation) for bending our molding, you spray on glue to hold your material for covering.
You secure it to the doors with a 3m product that is a heavy duty velcro. Glue one strip to the door panel and another to the door. Easy on and off.
It is used to make numerous other car goodies, consoles,speaker holders,arm rests.
CCLINPLASTICISOURFRIEND

Lots of good suggestions here. I really like the idea of using ABS or PVC and velcro. That would make securing the door panels so much easier than all those silly clips.

-Rusty (IMG:style_emoticons/default/smoke.gif)
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Gint
post Oct 11 2004, 08:41 PM
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What about plain ole plexiglass? Also formable with heat. Cheap enough (last time I bought some).
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bondo
post Oct 11 2004, 09:02 PM
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I used to have a car made of ABS.. sunlight makes it brittle. If it's covered in vinyl it'd be fine, but don't leave it exposed.
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campbellcj
post Oct 11 2004, 09:19 PM
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I had some panels made with wood cores for the flat portion and then the original curved top piece was reused. ABS would probably be even better if moisture is a concern.
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boxstr
post Oct 11 2004, 10:24 PM
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The ABS cuts by just scoring with a sharp utility knife and then snapping , kind of like drywall. It sands, drills and is very pliable when heated with a blow torch.
The velcro material is a 3M product trademarked as Dual lock tape.
I think moisture will always be an issue. Washing the car, rain or just being left outside overnight can have an effect on wood or paper based products.

CCLINABS4914
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Red-Beard
post Oct 11 2004, 10:45 PM
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I think you'll find "Dr. Evil" has a line on new production, CNC, door panel boards...covered in new vinyl or leather...
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Aaron Cox
post Oct 11 2004, 10:48 PM
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QUOTE(Red-Beard @ Oct 11 2004, 09:45 PM)
I think you'll find "Dr. Evil" has a line on new production, CNC, door panel boards...covered in new vinyl or leather...

ive seen them (IMG:style_emoticons/default/agree.gif) ...Gravy baby!

check what he can do for your interior too! (see my sig)

[/blatantadvertising]
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rhaas
post Oct 12 2004, 06:33 AM
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the currugated plastic that is used in sign shops works very well. plus it is lightweight. that is what I used in my 911. been working great for 3 years.
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Chris914n6
post Oct 12 2004, 10:43 PM
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Sintra - foamed PVC plastic used in the sign industry, pretty cheap. Used it on my custom door panels. Easy to work with. Comes is a rainbow of colors lol. If I hadn't of lost access to the CNC Router I would be making these. (IMG:style_emoticons/default/sad.gif)

Coroplast - name brand for the corogated plastic sheet (like cardboard boxes), also a sign industry thing. $10 a 4'x8'.

3M velcro stuff is called DualLock, has a mushroom head design. Have some that I was going to use to attach the door panels but went a different route. Staples or Office Depot or...

Oh, the early OE door panels have a seperate steel top edge with a flat panel. The later are a one piece molded design.
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