I ordered 2 pieces of 12" by 36" sheet aluminum that is .050 thick from McMaster Carr and a roll of maroon vinyl from Jim Carter. I then removed the old panel and traced it over the aluminum sheet with a sharpy. Cut out the aluminum with a nice new metal blade for thin metal with a jigsaw and then drilled the appropriate mounting holes on my drill press. Did a quick test fit.
Steve,
Nice work on those door panels. I'm basically in the same boat with my door panels. I've ordered the .050" aluminum and have the material to cover the panels. Here's a couple questions for you:
Did you cut the aluminum panel the same size as the cardboard? I was thinking about adding 1/16" all the way around to keep the panel in the frame.
Did you have to clamp the aluminum when you cut it with the jig saw? It seems like it could jump around a bit or wander.
Thanks,
