How To Make Custom Auto Door Panels

Cut the template with a utility knife.

How to make custom auto door panels.

To custom make door panels that are strong enough for everyday use and or abuse use fiberglass mat to reinforce the high stress areas like the door pull or armrest for instance cut the fiberglass mat into several small pieces and. But using some readily available components you can achieve professional looking results. Mark simpson demonstrates on a 1962 oldsmobile door panel how to create custom car door panels using abs board and pre sewn top stitch panels from ez boy interiors. Be sure to mark all holes for the clips and door handles.

Place one 48 by 48 by 1 8 inch hardboard on a worktable. For most classic car restorers sewing together upholstery is an unlearned skill. Door panels can be a real pain to build when you consider the types of materials available in sheet form. If you want to construct a panel without using an old one tape kraft paper to the inside of the door and trace the pattern onto the paper.

To make the holes i used a gasket punch at first and for the larger holes but for small door panel clip holes i just drilled 1 2 holes like the original had and cleaned the edge with a sharp knife. Most factory cardboard panels have long since rotted away or are warped beyond. However with a little instruction and a broad selection of car interior upholstery parts the task is made easier than you might think. The cardboard cut pretty easy with a few passes of a new utility knife.

This series of videos will walk you through building custom interior door panels.