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Tired of Ugly Door Panels for AD Trucks #1286025
Sun Nov 04 2018 01:04 PM
Sun Nov 04 2018 01:04 PM
S
sstock  Offline OP
Shop Shark
Joined: Jan 2013
Posts: 1,228
Gig Harbor, WA
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 (777 downloads)
1 year old cardboard panels
IMG_1224.jpg (790 downloads)
Finished Passenger Side
IMG_1226.jpg (766 downloads)
Tracing old door panel over .050 Aluminum Sheet 12"by 36"
IMG_1227.jpg (740 downloads)
Cut and drilled out aluminum door panel
IMG_1228.jpg (719 downloads)
Test Fitting
Last edited by sstock; Sun Nov 04 2018 01:07 PM.
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286026
Sun Nov 04 2018 01:06 PM
Sun Nov 04 2018 01:06 PM
S
sstock  Offline OP
Shop Shark
Joined: Jan 2013
Posts: 1,228
Gig Harbor, WA
More pictures

Attached Files
IMG_1229.jpg (716 downloads)
Attaching vinyl to panel with contact cement
IMG_1230.jpg (744 downloads)
Assembling metal frame around door panel
IMG_1233.jpg (736 downloads)
Finished Driver's Side installed
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286028
Sun Nov 04 2018 01:10 PM
Sun Nov 04 2018 01:10 PM
B
Brad Allen  Offline
Shop Shark
Joined: Sep 2006
Posts: 3,489
Salt Lake City, Utah
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
Sun Nov 04 2018 03:49 PM
MNSmith  Offline
"Hey! I sound like Darth Vader!!
Joined: Oct 2005
Posts: 2,598
So Cal
Looks good!

Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286313
Tue Nov 06 2018 03:48 AM
Tue Nov 06 2018 03:48 AM
Achipmunk  Offline
Extreme Gabster
Joined: Dec 2001
Posts: 14,648
Boiling Springs, S. C. 29316
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
Tue Nov 06 2018 02:49 PM
S
sstock  Offline OP
Shop Shark
Joined: Jan 2013
Posts: 1,228
Gig Harbor, WA
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.
Re: Tired of Ugly Door Panels for AD Trucks [Re: sstock] #1286431
Wed Nov 07 2018 02:35 AM
Wed Nov 07 2018 02:35 AM
M
miraclepieco  Offline
Shop Shark
Joined: Dec 2014
Posts: 457
OR
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
Wed Nov 07 2018 03:05 AM
N
ndkid275  Offline
Shop Shark
Joined: Jan 2013
Posts: 1,330
Northern VA
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
Thu Nov 08 2018 08:53 PM
T
tom moore  Offline
Shop Shark
Joined: May 2006
Posts: 556
New Hampshire
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
Thu Nov 08 2018 10:38 PM
tclederman  Offline
Boltergeist
Joined: Sep 2001
Posts: 27,925
Jarvisburg, NC
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 50 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.
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