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Tired of Ugly Door Panels for AD Trucks #1286025 Sun Nov 04 2018 01:04 PM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
Last year I finished the cab off restoration of my 53 3100. When I got to the interior, I ordered a nice maroon seat cover from Jim Carter and a new headliner and door panels. I seemed pretty happy with it at the time but now was not happy with how the cardboard door panels wore in just a year. The quality of cardboard is not really good, if you get water on them when you open the door, you will see what I mean. Eventually the cardboard started to pull out of the frames and started to look bad. 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. Removed and to the workbench to clean the aluminum with some paint surfacer cleaner. I then applied some contact cement to the aluminum and the back side of the vinyl and set aside to dry for 20 minutes. After the contact cement was dry, I carefully laid the vinyl over the aluminum panel and rolled it in with my linoleum roller to press it in and get out any bubbles. This part it is best to have a helper hold the vinyl off the sheet and just touch one corner of the vinyl to the sheet and slowly start rolling the vinyl on as your helper allows more of the vinyl to touch the sheet until it is completely attached. Once attached, you can trim the excess off with a new razor blade and cut out the holes with an exacto knife. Next assembled the metal frame around the door panel and secure the frame on the backside with some duct tape. Then install the panel to the truck, arm rest, window cranks and door handles. It took a couple hours and cost about $80 but looks far better than it did. The key is to get alluminum sheet that is no thicker than .050 so when you add the vinyl it still fits in the metal trim. Hope this helps somebody down the road, cheers.

Steve


Attached Files
IMG_1225.jpg (19.68 KB, 838 downloads)
1 year old cardboard panels
IMG_1224.jpg (30.32 KB, 851 downloads)
Finished Passenger Side
IMG_1226.jpg (26.75 KB, 824 downloads)
Tracing old door panel over .050 Aluminum Sheet 12"by 36"
IMG_1227.jpg (25.13 KB, 798 downloads)
Cut and drilled out aluminum door panel
IMG_1228.jpg (22.21 KB, 776 downloads)
Test Fitting
Last edited by sstock; Sun Nov 04 2018 01:07 PM.

1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286026 Sun Nov 04 2018 01:06 PM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
More pictures

Attached Files
IMG_1229.jpg (26.01 KB, 771 downloads)
Attaching vinyl to panel with contact cement
IMG_1230.jpg (23.17 KB, 800 downloads)
Assembling metal frame around door panel
IMG_1233.jpg (24.47 KB, 790 downloads)
Finished Driver's Side installed

1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286028 Sun Nov 04 2018 01:10 PM
Joined: Sep 2006
Posts: 3,516
B
Brad Allen Offline
Shop Shark
Looks very nice, thanks for the pictures and details.

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286045 Sun Nov 04 2018 03:49 PM
Joined: Oct 2005
Posts: 2,650
MNSmith Offline
"Hey! I sound like Darth Vader!!
Looks good!

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286313 Tue Nov 06 2018 03:48 AM
Joined: Dec 2001
Posts: 14,720
Achipmunk Offline
Extreme Gabster
Pretty Slick......I had thought about doing something like that but you have the "proof in the pudding". Great job and thanks for the details.


1937 Chevy Pickup
1952 Chevy Panel
Pictures in my Photobucket
1950 Chevy Coupe

52 Chevy Panel

I'd rather walk and carry a Chevy hub cap than ride in a Ferd.
I can explain it to you, but I can't understand it for you smile
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286360 Tue Nov 06 2018 02:49 PM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
Thanks all for your comments.
I can't say enough good about McMaster Carr, they seem to have just about everything for any fabrication, quick shipping and reasonable prices too.
Steve

Last edited by sstock; Tue Nov 06 2018 02:51 PM.

1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286431 Wed Nov 07 2018 02:35 AM
Joined: Dec 2014
Posts: 538
M
miraclepieco Offline
Shop Shark
Big improvement over the cardboard.


1951 Chevy Panel Truck
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286433 Wed Nov 07 2018 03:05 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I am curious to see how you tackle the cardboard on the roof!

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286624 Thu Nov 08 2018 08:53 PM
Joined: May 2006
Posts: 601
T
tom moore Offline
Shop Shark
you can go into production and sell them. looks great.

Last edited by tom moore; Thu Nov 08 2018 08:53 PM.
Re: Tired of Ugly Door Panels for AD Trucks [Re: ndkid275] #1286634 Thu Nov 08 2018 10:38 PM
Joined: Sep 2001
Posts: 28,449
tclederman Offline
Boltergeist
Originally Posted by ndkid275
I am curious to see how you tackle the cardboard on the roof!

Ditto

Nice work, Steve
And, nice explanation.

Ditto on ndkid275's post: "I am curious to see how you tackle the cardboard on the roof!"


Tim
1954Advance-Design.com
1954 3106 Carryall Suburban - part of the family for 48 years
1954 3104 5-window pickup w/Hydra-Matic - part of the family for 14 years
Z-series (54/55) GMC 350 (2-ton) COE - now part of Dave's family
- If you have to stomp on your foot-pedal starter, either you, or your starter, or your engine, has a problem.
- The 216 and early 235 engine are not "splash oilers" - this is a splash oiler.
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286638 Thu Nov 08 2018 11:05 PM
Joined: Feb 2016
Posts: 37
D
DavidBraley Offline
Wrench Fetcher
I like this. Bookmarking now...


-David

1948 2-Ton GMC

Horsepower determines your speed when you hit the wall. Torque determines the size of the hole you make...
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286892 Sat Nov 10 2018 06:10 PM
Joined: Mar 2011
Posts: 138
6
66flea Offline
Shop Shark
3/8 inch beadboard with the back routed out

Attached Files
0312171004.jpg (228.35 KB, 504 downloads)
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286894 Sat Nov 10 2018 06:12 PM
Joined: Mar 2011
Posts: 138
6
66flea Offline
Shop Shark
i made arm rests to match. i'll post when i find the picture

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287031 Sun Nov 11 2018 06:59 PM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
Hi Steve.
Nice work. Here's another idea: You can also use Formica counter top material. It is not expensive, comes in a standard thickness of .035", will not warp and it will flex without permanently bending nor developing the wavy bumps fiberboard gets. Cut it so the back side (the rough side) faces outward. If you want to paint it, sand the texture on the back until it is smooth, prime it and spray it after the pieces have been cut. Or coat it with contact cement and cover with vinyl as you've done. The headliner (as you know) has compound/complex curves. You can use a blow drier to help Formica bend to make those curves (the ones at the front) look right. I would not use aluminum on the headliner.

You can also still get upholstery grade fiberboard (here: https://www.perfectfit.com/15347/Chipboard-Car-Panelboard.html ) but the non-waterproof board must be sealed on both sides and at all edges well or it will shrink and warp.


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287044 Sun Nov 11 2018 09:14 PM
Joined: Apr 2005
Posts: 7,611
Justhorsenround Offline
Grease Monkey, Moderator General Truck Talk & Greasy Spoon
Isn’t Formica extremely brittle?🛠


Martin
'62 Chevy C-10 Stepside Shortbed (Restomod in progress)
'47 Chevy 3100 5 Window (long term project)


"I fought the law and the law won" now I are a retired one!
Support those brave men/women who stand the "Thin Blue Line" and lock up those on the wrong side of that line.

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287060 Sun Nov 11 2018 11:36 PM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I will give the Formica a try.... where do I find it?

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287071 Mon Nov 12 2018 12:26 AM
Joined: Jul 2000
Posts: 638
G
Gord&Fran Offline
Shop Shark
You can get Formica at almost any hardware store.

I used Formica to make washers to go between the vinyl upholstery and the window and door cranks. I drilled holes in the Formica with a 2.25" hole saw. I then smoothed the edges of the cut outs and drilled them to fit over the shafts. The washers protect the vinyl upholstery from chafing.

We used plywood "door skins" for the panels. Thin foam was glued to the plywood and the vinyl stretched over and glued on the back side. It worked OK, but I like the suggestions above more. If you do use door skins, note that the plywood bends easier in one direction than in the other. Make sure you orient the plywood the correct way. Of course, we did it wrong. dang


Gord
----
1954 1/2 ton 235 4 speed
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287085 Mon Nov 12 2018 01:43 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I may give it a try for roof and door skins. My skins and ceiling are falling apart after 1 year!

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287112 Mon Nov 12 2018 04:45 AM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
Formica is brittle but is more flexible than one might think. Please take a look at this scrap piece (which is 16" x 4") lying flat:
https://beta.photobucket.com/u/JonGoodman/p/67afae92-7408-4e27-8236-756b9c41d7cb
And here I have it sitting on a 2.5 inch tall piece of metal and I'm forcing it flat down on the table (making the bend around 30 ~ 35 degrees):
https://beta.photobucket.com/u/JonGoodman/p/de06daff-ddbd-4709-b4df-4bb67ff4979c
And here I am wrapping that same piece around the windshield trim molding (the one with the sharp bend):
https://beta.photobucket.com/u/JonGoodman/p/1fa19108-e620-48ef-bc04-e9696cff2e2b

As I said if you heat it with a blow dryer it becomes even more pliable. I'm certain there are instructions on the internet about this.


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287114 Mon Nov 12 2018 05:33 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I plan on trying to cover it with something, probably black vinyl like my seats. We shall see how this goes, I am debating on making the roof one piece or 2 pieces. if I glue 2 pieces up there, I can still cover it easily, thoughts?

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287123 Mon Nov 12 2018 12:34 PM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
Never though of formica, maybe that will even be better/cheaper than sheet aluminum, certainly cheaper for sure. Thinking of trying that on the roof panels because of the curves, thanks for that idea.
Building the roof panel in two pieces seems easier and will appear correct too. Plus you only handle and fit a smaller piece. Yeah, I'm really liking that idea. Thanks guys (Jon G.).

Last edited by sstock; Mon Nov 12 2018 12:40 PM.

1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: Gord&Fran] #1287125 Mon Nov 12 2018 12:39 PM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
Originally Posted by Gord&Fran
You can get Formica at almost any hardware store.

I used Formica to make washers to go between the vinyl upholstery and the window and door cranks. I drilled holes in the Formica with a 2.25" hole saw. I then smoothed the edges of the cut outs and drilled them to fit over the shafts. The washers protect the vinyl upholstery from chafing.

We used plywood "door skins" for the panels. Thin foam was glued to the plywood and the vinyl stretched over and glued on the back side. It worked OK, but I like the suggestions above more. If you do use door skins, note that the plywood bends easier in one direction than in the other. Make sure you orient the plywood the correct way. Of course, we did it wrong. dang

Super idea for crank washers, liking this much better than the cardboard ones.


1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287157 Mon Nov 12 2018 03:56 PM
Joined: Mar 2010
Posts: 8,316
5
52Carl Offline
Master Gabster
I may try to find aluminum sheet which is thin enough to fold the maroon vinyl over the edge, but still fit inside of the metal retainer. This will keep the vinyl from letting go of the glue and coming out of the edge of the retainer like mine always seem to do. The maroon vinyl which Jim Carter sells has extra material around the edge so that you could do this.
Carl

Last edited by 52Carl; Mon Nov 12 2018 03:58 PM.
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287158 Mon Nov 12 2018 04:01 PM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I found black Formica that I may try for roof so that I don’t have to put vinyl over it.

Re: Tired of Ugly Door Panels for AD Trucks [Re: ndkid275] #1287163 Mon Nov 12 2018 04:20 PM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
Originally Posted by ndkid275
I plan on trying to cover it with something, probably black vinyl like my seats. We shall see how this goes, I am debating on making the roof one piece or 2 pieces. if I glue 2 pieces up there, I can still cover it easily, thoughts?


If you have the center bow and rear retaining cover for the headliner, everything will work as it should. That center bow has a front and rear slot and the rear retainer is held in place with screws. Cover the Formica or paint it before you install it. If you use vinyl, I'd try to use a thinner vinyl than what is on your seat. Then install the rear section first and secure it with the rear retainer. The bow will slip in place next. This requires a bit of coordination and a helper might be good also. Then slip the front piece into the front bow slot and secure it with the windshield trim after you get it in place. If you have a shade flap, measure and carefully cut the holes for it before you mount the panel (this can be difficult so do take your time). One way is to attach double sided tape (on which the holes have been cut out already) to the place on the body where the flap will mount, press the headliner panel in and then remove it to cut the holes. Hint: on the side of the double sided tape that sticks to the body...stick this somewhere on your face first. The oil will cause it to just "sort of" stick and then it will stick more firmly to the headliner panel when you remove it. Oh, and also...big important note...this job goes better if you remove the windlace and replace it once you're finished. It really is not fun trying to get the headliner panel on the other side of that windlace rubber.


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287800 Sat Nov 17 2018 05:40 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
Just purchased some Formica to see how well it works. Fingers crossed!

Chris

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287899 Sun Nov 18 2018 12:04 AM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
I'm sure you'll do fine. Here's a tip: get a jig saw (we used to call them saber saws also) and a fine metal cutting blade. Work carefully cutting the stuff and go slowly. If it is important to you to keep the front side from chipping when it is cut, get 1/4 inch plywood and clamp your Formica between two sheets of it. We used to do that for small or thin pieces. Did I mention go slowly?


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287916 Sun Nov 18 2018 01:01 AM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
Good info Jon, for tight curves and the door and window crank holes use a dremmel.


1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287985 Sun Nov 18 2018 07:29 PM
Joined: Sep 2007
Posts: 369
R
Rusty Shackleford Offline
Shop Shark
I used black Formica/Aborite. I made a template of the panel with plywood, clamped the laminate to the plywood and used a router with a laminate bit with an edge guide. Because I needed black, I used the Formica as is.


It's a small world, but I wouldn't want to paint it.
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1287996 Sun Nov 18 2018 10:15 PM
Joined: Apr 2009
Posts: 512
H
Hookalatch Offline
Shop Shark
Nice job on the door panels. I did basically the same thing on my 1952 3100. I did bend the aluminum to conform to the curve present in both my doors and door panel frames. It seems to be a much more pronounced crease in my truck then your 1953. I thought they were the same. I used the same covering as the seat and did take the vinyl over the edge. Tight fit in the frame but it worked. I have tried to attach a picture but not sure it will work.

Attached Files
IMG_3004.JPG.JPG (66.56 KB, 384 downloads)
IMG_3005.JPG.JPG (83.88 KB, 376 downloads)
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1288027 Mon Nov 19 2018 03:27 AM
Joined: Dec 2001
Posts: 14,720
Achipmunk Offline
Extreme Gabster
I'm even rethinking my panels................Steve, see what you got started.


1937 Chevy Pickup
1952 Chevy Panel
Pictures in my Photobucket
1950 Chevy Coupe

52 Chevy Panel

I'd rather walk and carry a Chevy hub cap than ride in a Ferd.
I can explain it to you, but I can't understand it for you smile
Re: Tired of Ugly Door Panels for AD Trucks [Re: Rusty Shackleford] #1288042 Mon Nov 19 2018 04:41 AM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
Originally Posted by Rusty Shackleford
I used black Formica/Aborite. I made a template of the panel with plywood, clamped the laminate to the plywood and used a router with a laminate bit with an edge guide. Because I needed black, I used the Formica as is.


That's right! If you have a router and a ball bearing laminate bit, it makes the work slick and quick. Just be certain to use the straight bit and not the edge bit...


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1288074 Mon Nov 19 2018 03:37 PM
Joined: Oct 2005
Posts: 2,650
MNSmith Offline
"Hey! I sound like Darth Vader!!
ABS here.

Attached Files
1952suburban506.jpg (42.93 KB, 442 downloads)
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1288142 Tue Nov 20 2018 02:34 AM
Joined: Aug 2018
Posts: 246
2
2ManyTrucks Offline
Shop Shark
nice door panels!
i was also concerned with the cardboard door panels i ordered online, so i did an intermediate fix, i just glued some old vinyl school bus seat material to the cardboard before installing the metal trim, time will tell if that's sufficient
but if i do it again i'm gonna go this aluminum sheet method, many more seats in the school bus to cut vinyl from, and two colors to choose from, grey or traditional brown smile

about the roof... yeah... i did such a bad job on the roof, but in my defense, it was my first one, i did it alone, it's a work truck so it didn't need to be show quality
i'm sure the second time will be much better smile
-s


1430s, 1420, 9430
-2MT
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1290459 Mon Dec 10 2018 01:11 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I just cut and made the two roof panels in Formica. I might attemp to install the tomorrow night. I hope to get door seals in place so I can pick my wife up from the airport on the 20th. I will post pictures

Last edited by ndkid275; Mon Dec 10 2018 01:12 AM.
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1290705 Tue Dec 11 2018 10:26 PM
Joined: Dec 2013
Posts: 638
HandyAndy Offline
Shop Shark
Hey Chris,

Let's see those pics! I've been struggling with the door panels too. This past summer I replaced the door panels (purchased from a preferred vendor). They looked okay for a while, but the top corners kind of puckered when I tightened them. I just noticed the the driver's side panel is creeping out of the SS frame.

Are you guys over-sizing these custom made panels?

I appreciate all the dialog this thread has created. There are some great ideas out there on door panels.

Thanks,


Andy

His: 1947 Chevrolet 3100
Hers: 2008 American Saddlebred

"A Jack of all trades is a master of none, but oftentimes better than a master of one." - Benjamin Franklin
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1290727 Wed Dec 12 2018 01:33 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
I am trying to get it put in ASAP. I am considering putting aluminum panels behind the Formica for the door panels to stiffen it up.

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1290748 Wed Dec 12 2018 04:17 AM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
Hint...if you're using fiberboard panels, consider putting a rubber faucet washer (3/4" diameter) behind each trim screw so the force of the screws doesn't pull them inward too much and deform them.


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: Jon G] #1290981 Thu Dec 13 2018 10:18 PM
Joined: Dec 2013
Posts: 638
HandyAndy Offline
Shop Shark
Originally Posted by Jon G
Hint...if you're using fiberboard panels, consider putting a rubber faucet washer (3/4" diameter) behind each trim screw so the force of the screws doesn't pull them inward too much and deform them.

Jon G, thanks for the tip! In my case, I actually thought about something like that. At least my hindsight is 20/20!! wink


Andy

His: 1947 Chevrolet 3100
Hers: 2008 American Saddlebred

"A Jack of all trades is a master of none, but oftentimes better than a master of one." - Benjamin Franklin
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1290988 Thu Dec 13 2018 11:15 PM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
Front panel is in! Looks great!


Edited: added pictures of back panel. I like it, not too bad, had one minor issue with mid measurement. The other was accidentally dropping the heat gun on my ankle. Had to yell without moving and dropping the panel. FYI, I yelled like a ****!

Attached Files
C38BE77B-B155-4F3E-91B2-5EC40543953A.jpeg (175.08 KB, 276 downloads)
3B7CB207-AB63-4A94-91FD-347355BBD8AB.jpeg (104.28 KB, 294 downloads)
Last edited by ndkid275; Thu Dec 13 2018 11:44 PM. Reason: Added pictures
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1290998 Fri Dec 14 2018 12:45 AM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
That looks super! Good work and you didn't have to paint that, did you?


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291001 Fri Dec 14 2018 12:55 AM
Joined: Dec 2013
Posts: 638
HandyAndy Offline
Shop Shark
Nice work, Chris!

That really turned out great. Any issues with cutting the Formica? What did you use for the pattern?

Keep us posted on the door panels too. I've never cut sheet aluminum before and I suppose there's a preferred technique.

Thanks for sharing,


Andy

His: 1947 Chevrolet 3100
Hers: 2008 American Saddlebred

"A Jack of all trades is a master of none, but oftentimes better than a master of one." - Benjamin Franklin
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291013 Fri Dec 14 2018 03:09 AM
Joined: Jan 2013
Posts: 1,385
N
ndkid275 Offline
Shop Shark
So here is what I did.

Since I had cardboard that was falling apart, I used that as a template and adjusted it as needed since my truck isn’t square. Next, I used a drummel with cutting wheel to follow the line (very slow). Finally, held it close and heated the ends to mold it as needed. No painting!

Things I recommend. Make back panel longer due to cross member support. It slides in farther than I excepted. My cardboard must not have been slide in far enough.

If you get the 4x8 piece you can do both doors and roof panels.

I will post more once I do side panels. I am debating on doubling up Formica instead of aluminum.

Chris

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291028 Fri Dec 14 2018 05:04 AM
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ndkid275 Offline
Shop Shark
Anyone know how the cardboard kick panels are attached? Just curious since I have extra Formica that I might as well use.

Chris

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291141 Sat Dec 15 2018 01:10 AM
Joined: Mar 2014
Posts: 1,064
J
Jon G Offline
Shop Shark
I don't know Chris. I've owned a few of these trucks and none had kick panels of any sort. They were all just painted. I always paint the interiors in catalyzed enamel or catalyzed urethane help keep from scuffing as much. The first one I saw with kick panels may have been in the early 1960s. A friend bought a 1965 brand new and got the deluxe model...it had A/C and kick panels. One of the nicest pickups I've ever seen until he traded it in on a 1968. Gas mileage was comically bad but you could ride in the thing all day long and not be tired.


Jon

1952 1/2 ton with 1959 235
T5 with 3.07 rear end
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291172 Sat Dec 15 2018 06:07 AM
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ndkid275 Offline
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Jon,

I have mine painted, I was just curious to see what it would look like and how they actually did it.

Chris

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291294 Sun Dec 16 2018 04:34 AM
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ndkid275 Offline
Shop Shark
FYI, trying to get the visor screws in the right spot cracks the Formica easily!

Chris

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291340 Sun Dec 16 2018 06:46 PM
Joined: Oct 2005
Posts: 2,650
MNSmith Offline
"Hey! I sound like Darth Vader!!
Time and vibration will end up doing the same.

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291803 Thu Dec 20 2018 02:53 AM
Joined: Dec 2013
Posts: 638
HandyAndy Offline
Shop Shark
Originally Posted by sstock
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,


Andy

His: 1947 Chevrolet 3100
Hers: 2008 American Saddlebred

"A Jack of all trades is a master of none, but oftentimes better than a master of one." - Benjamin Franklin
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291809 Thu Dec 20 2018 03:51 AM
Joined: Jan 2013
Posts: 1,381
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sstock Offline OP
Shop Shark
No, the aluminum is cut the same size as the replacement cardboard door panels, I would be careful about cutting it oversize, worrying that the metal frame would not go around. I did clamp it along a piece of 3/4" plywood and used a fine tooth metal jig saw blade. Another thing I did that I forgot to mention was place 2ea 3/8"thick hard bumpers above each door handle mechanism to give it enough clearance between the sheet aluminum and handle mechanism,otherwise the door handle will not want to return on its own after opening the door. The other fellow above bent his sheet aluminum to fit over the door handle mechanism.


1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1291941 Fri Dec 21 2018 10:17 PM
Joined: Mar 2011
Posts: 138
6
66flea Offline
Shop Shark
the arm rests are made of oak with the same merlot stain as the 3/8 beadboard

Attached Files
20170912_160358.jpg (188.68 KB, 296 downloads)
20170914_122123.jpg (274.14 KB, 296 downloads)
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1296283 Sat Jan 26 2019 02:00 AM
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Posts: 1,385
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ndkid275 Offline
Shop Shark
Just got completed with the Formica door panels! Looks really good. Placed rubber washers behind it so I didn’t break it.

Chris

Attached Files
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1309888 Tue May 07 2019 01:07 AM
Joined: Dec 2013
Posts: 638
HandyAndy Offline
Shop Shark
sstock, thanks for the tip!

The .050" aluminum really worked out nice for me. I still have quite a bit work to do on my interior, but this is a great start.

Attached Files
Aluminum Covered Door Panel.jpg (155.92 KB, 180 downloads)

Andy

His: 1947 Chevrolet 3100
Hers: 2008 American Saddlebred

"A Jack of all trades is a master of none, but oftentimes better than a master of one." - Benjamin Franklin
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1309902 Tue May 07 2019 02:16 AM
Joined: Jan 2013
Posts: 1,381
S
sstock Offline OP
Shop Shark
Well done Andy, looks so much better than cardboard.


1953 Chevrolet 3100
261 cu inch, sm420, 3.55 rear, omaha orange, still 6 volt, RPO green glass, side carrier spare
https://www.youtube.com/watch?v=Bli...n05i04t1aokgm4p04jiwgffwhyyih5xbk0h00410
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