Door Panel repair

[Big_John]

As before, I placed the old panels over the new and traced it out with a pencil and cut it with a utility knife and tin snips. Sorry no pics. The new board came from here: COWLBOARD WATERPROOF OEM NATURAL 32X48 | Miami Corp

The last time, I cut the rectangular clip holes out by hand. This time, I bought a little router attachment for my Dremel tool and 3D printed a template for the router. Much easier!

 

[Big_John]

This time, I used a construction adhesive to join the steel top to the board. It was easier although took overnight to setup. A 273 head holds it down.

As before, a strip of aluminum roof tape was added over the joint on both sides.




This time, I fitted the clips on the bare panel. This saved a ton of time later. Once in place, I dabbed a little E-6000 glue on the clips, then ran a strip of aluminum tape over it. This will hold them in place, but still can be adjusted if needed and should make it a little stronger.

 

[Big_John]

Where the vinyl wrapped around the board was problematic. I had the same issue the last time... This time the vinyl was a little stiffer from age and not as much material to wrap.

After a bit of thinking, I used some vinyl repair cement on the wrap over. More aluminum tape was used to hold it in place until it dried... and then I just left it on there. This worked fantastic. https://www.amazon.com/dp/B004BC4UMC?ref=ppx_yo2ov_dt_b_fed_asin_title

Once the vinyl was on, I needed to prepare to get the color right. The pearl white had yellowed and wore.

I scrubbed everything with a brush mounted to my polisher and some Meguiars all purpose cleaner. (I'm doing a seat here)

This was wiped down with SEM vinyl prep and then sprayed with Bulldog adhesion promoter. Then sprayed with paint from Kolor Korrect-Your Source For Classic Car Paint which is a lacquer with flex agent added. Not cheap!!!

First coat was a white base, followed by a pearl coat. Sorry, no pics during the painting.

I wasn't expecting the wrinkles!!!

A day later and the wrinkles were gone. Whew!

All finished!

 

[57fury440]

Your panels look great. I have to admit the popsicle sticks cracked me up.

 

[fury fan]

Looks like somebody might've polished the metal bits also, to make the vinyl repair look all the much better.

 

[Ripinator]

Where the vinyl wrapped around the board was problematic. I had the same issue the last time... This time the vinyl was a little stiffer from age and not as much material to wrap.

After a bit of thinking, I used some vinyl repair cement on the wrap over. More aluminum tape was used to hold it in place until it dried... and then I just left it on there. This worked fantastic. https://www.amazon.com/dp/B004BC4UMC?ref=ppx_yo2ov_dt_b_fed_asin_title

Once the vinyl was on, I needed to prepare to get the color right. The pearl white had yellowed and wore.

I scrubbed everything with a brush mounted to my polisher and some Meguiars all purpose cleaner. (I'm doing a seat here)

This was wiped down with SEM vinyl prep and then sprayed with Bulldog adhesion promoter. Then sprayed with paint from Kolor Korrect-Your Source For Classic Car Paint which is a lacquer with flex agent added. Not cheap!!!

First coat was a white base, followed by a pearl coat. Sorry, no pics during the painting.

I wasn't expecting the wrinkles!!!

A day later and the wrinkles were gone. Whew!

All finished!

Amazing work, John! How did you re-attach your red door reflectors?

 

[3175375]

Where the vinyl wrapped around the board was problematic. I had the same issue the last time... This time the vinyl was a little stiffer from age and not as much material to wrap.

After a bit of thinking, I used some vinyl repair cement on the wrap over. More aluminum tape was used to hold it in place until it dried... and then I just left it on there. This worked fantastic. https://www.amazon.com/dp/B004BC4UMC?ref=ppx_yo2ov_dt_b_fed_asin_title

Once the vinyl was on, I needed to prepare to get the color right. The pearl white had yellowed and wore.

I scrubbed everything with a brush mounted to my polisher and some Meguiars all purpose cleaner. (I'm doing a seat here)

This was wiped down with SEM vinyl prep and then sprayed with Bulldog adhesion promoter. Then sprayed with paint from Kolor Korrect-Your Source For Classic Car Paint which is a lacquer with flex agent added. Not cheap!!!

First coat was a white base, followed by a pearl coat. Sorry, no pics during the painting.

I wasn't expecting the wrinkles!!!

A day later and the wrinkles were gone. Whew!

All finished!

Great job! I am grateful that I have a black interior as white appears to show variances more.

 

[Big_John]

Amazing work, John! How did you re-attach your red door reflectors?

E-6000 glue. They seem to be holding well.

 

[Samplingman]

Excellent work! What is this attachment and where can I get one?

 

[Big_John]

Excellent work! What is this attachment and where can I get one?

View attachment 684069

Amazon! https://www.amazon.com/gp/product/B00X123JR0/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

It's handy... The bristles are just about the right firmness, but not too stiff.

 

[D Cluley]

Looks good. How did you detach the vinyl from the metal top piece?

 

[USSMOPAR]

please come work on my car....your attention to detail is a fine example of craftsmanship!

 

[Big_John]

Looks good. How did you detach the vinyl from the metal top piece?

After 60 years, the adhesive is dried out and it comes apart pretty easily. You still have to be careful not to stretch it, but for the most part it peels right off.

 

[3175375]

After 60 years, the adhesive is dried out and it comes apart pretty easily. You still have to be careful not to stretch it, but for the most part it peels right off.

I had to remove the Masonite from the steel on my car too, and it is not difficult, but you must be patient and take your time.

I replaced the Masonite with abs plastic. You can see it on my project page - Elwood. A 68 Fury II 4 door sedan. Here (post #36):

Elwood - 1968 Fury II 4 door sedan

 

[Big_John]

I had to remove the Masonite from the steel on my car too, and it is not difficult, but you must be patient and take your time.

I replaced the Masonite with abs plastic. You can see it on my project page - Elwood. A 68 Fury II 4 door sedan. Here (post #36):

Elwood - 1968 Fury II 4 door sedan

From reading that thread a while ago, I saw that you used construction adhesive to fasten the steel top to the board and did that myself. Thanks for that!

 

[D Cluley]

I used 3 or 4 screws & nuts and then taped the seam between the metal and the new masonite. Also added a thin layer of foam to help smooth out that seam.

 

[Big_John]

Also added a thin layer of foam to help smooth out that seam.

I thought about doing that. The issue was there wasn't a lot of material to wrap around the panel, so adding any foam might make that even worse.