Has anybody here made door panels from ABS, carbon fiber, or any other material? While mine are nice Katzkin leather panels, the fiber board is falling apart, the clips are missing or falling off, and the leather is losing it's bond with the board. I'd much rather have a nice, simple piece of plastic screwed to the door shell and be done with it. Can any of you share pictures if you do have something like this done? Trying to get ideas. I'm thinking for cost sake, just some simple ABS plastic. I'm just not sure where to find it local, so it will probably have to be ordered and shipped. Or, give me some creative ideas for materials to use, other than ABS sheets, something I could maybe find in a local hardware store, that is evading my mind.

 

I have no pics but have seen a good bit of people on here make some. Search in the "build threads" for some inspiration.

 

Yeah, I have seen it done, and my fiber boards are falling apart as well. In for win. You could be a baller and use diamond plate to match the floor pans that blow out from having too much nos...

 

(Posting from my phone.)

Diamond plate and miatas do not mix

 

People said that about RX7s once, Brainy, then the Truckasaurus Rex came into being.

 

I've seen them made from sheet aluminum. Looks surprisingly good.

 

By that logic, the only door-cards we should have access to would be crushed velvet with pink tiger-stripes.

 

Just had an idea... plexiglass? It's cheap and local, easy to source. Of course it's clear, but not after a good coat of paint or a covering of some type of fabric with some spray adhesive. Spray the back of the glass to keep a smooth and shiny surface. Anybody see any problem with using plexi? Or could that be a possible danger in an accident? Since it tends to break into sharp edges?

 

I'm very interested in this... since I will not be using speakers, will have power windows, only need to make a cut for the door pull + handle.

 

My biggest motivation for this is that aside from the actual fiber board falling apart, the damn upper section is completely separate from the lower section now, after I removed the panel the other day to inspect my window regulator assembly. The last of the 5 or 6 tabs that the screws go into on the upper part broke off, so now I just snap the lower section in, and slide the upper part over it. I could make a false move with the top down and lose that whole upper part going down the road.

 

I made mine with aluminum. Mostly to delete the door handle and speaker and make it look presentable.

 

pics after it hits another wall?

yeah...





not in the least. I'd say if you have a mullet, you can use diamond plate door cards and floormats.

 

I think I ruled out acrylic glass, just too easy to crack. I did find some .080 for a good price, but I would still be left having to paint it, and avoid cracking it while drilling holes and shaping it. Might just buy the ABS online and be done with it. Only question now is thickness. Not sure if I should do 1/8'' or 3/16''. I want it to be rigid enough that it won't wrinkle and wave between screws, in the large open areas of the door panel. Not sure how thick it would need to be to be stiff enough. I think 1/8'' would do it, but I might feel better about 3/16'', even though it costs a good bit more. $60 for 48x48 at 1/8'' vs $92 for same dimension but 3/16'' thick. Getting it from Grainger, so I can pick it up local and save on shipping. I'll keep you guys up to date with my handy work, when I get it. I'm thinking leather loop strap for the pulls, and I will have to come up with something for the speaker grills. Also not sure how I will attach the upper piece of the panel to the ABS, as it has no tabs to screw into. Maybe velcro will work as a easy to remove fastener.

 

Why not get some aluminum from home depot and paint/glue some carpet/other similar material to it?

 

There is at least one guy (maybe from Oz or UK) that did the plexiglass and left it clear.

There was another guy that made some really nice ones out of sheet aluminum and then shared a template file for CAD. His had some pretty trick speaker holes.


Another option might be the alumilite style materials people use for front splitters.

 

As far as Plexiglas goes, Ive attempted to use Opetx and Duraplex (sp?) in the past to replace a rear window with no luck. One of the two (Duraplex I think but not sure at all) was freaking imposable to cut without it cracking, I tired one of those cutting tools, a fine tooth saw ect and nothing worked. The other one could be cut with a fine tooth saw as long as the blade was kept lubed with WD-40 or a rotory tool. Also, Plexiglas would probably shatter/crack in cold weather or an accident and rattle like crazy all the damn time. Aluminum seems like a nice choice.

 

Dont cut it...melt it. Use a good soldering gun and melt away.

 

I'm pretty sure I don't want aluminum. No dent resistance, and it would have to either be painted, or brushed to look decent. Plus it scratches easy and they show up easily. ABS is the route I am taking. Already black, the color I want, won't dent or crack with abuse, not easily scratched, and if it does, can easily be painted.

 

Tried that, but I didn't want to be breathing in whatever toxic crap the fumes contained.

 

Yeah thats a problem, definitely gotta cut it in a ventilated area with a fan blowing at your face to keep the fresh air going.