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View Full Version : Need help constructing fiberglass door panels



basscort2009
07-12-2009, 07:05 PM
ok so i have a 1988 gmc jimmy that im trying to bring back to life, i spent the last 3 days rewiring the 21 year old mess. i looked at the door panels and they were just trashed! awful and non repairable, so i ripped them off

now i need to know how to make some panels for them. its just the bare metal on the door and have no idea where to start.

ANY help would be awesome, and pics with ideas would help as well. either way post up and help me out.

dappa5
07-12-2009, 08:12 PM
do you still have the old panels?

tc3k101
07-12-2009, 08:14 PM
make a mock up from old panels and go frmo there or glass over the old panels....

dappa5
07-12-2009, 08:16 PM
^^^yup you'll need old panels or junk yard replacements

basscort2009
07-12-2009, 08:43 PM
well the other ones were crusty and falling apart so i thought it would be bad to do that and them crust away lol. i got some other advise from a fellow competitor i roll with to use cardboard and make the mock panel from that then use mdf, like 3/8 or somthing for the panel. what is the pros and cons of that way?

ramos
07-13-2009, 11:39 AM
pro- you can make it pretty much what ever your little heart desires.

con- it takes an arse ton more time to get the fitment and everything just right.

:)

basscort2009
07-13-2009, 01:51 PM
well i decided to go with mdf door panels and custom mdf speaker pod at the bottom. got the cardboard mock cutout and gonna go today to home depot and get the wood. another question is how thick should the mdf be? is 3/8 thick enough?

tylork92
07-13-2009, 01:56 PM
3/8 should be fine...however it might be better for you to go to the junk yard to and get a set of panels and customize them unless its just a flat piece neways....post pics of the doors.

basscort2009
07-13-2009, 01:58 PM
3/8 should be fine...however it might be better for you to go to the junk yard to and get a set of panels and customize them unless its just a flat piece neways....post pics of the doors.

yea i looked and apparently not even 8 (yes 8) of the local junkyards have anything close to a nice door panel worth reviving for my 21 year old jimmy lol. yea the mdf will be flat peice. then FG in the speaker pods, then cover with vynil. i have been taking pics of this project so far, i have the pics but will probly do a build log in a couple days or so.

tylork92
07-13-2009, 03:27 PM
yea i looked and apparently not even 8 (yes 8) of the local junkyards have anything close to a nice door panel worth reviving for my 21 year old jimmy lol. yea the mdf will be flat peice. then FG in the speaker pods, then cover with vynil. i have been taking pics of this project so far, i have the pics but will probly do a build log in a couple days or so.

yea sounds good...you gonna make a armrest somehow?

basscort2009
07-13-2009, 03:31 PM
yea i will make one for both sides. probly just 2 little triangles that hold up a 3 inch by 12 inch peice wrapped with some pollyfill forcomfort or somthing

basscort2009
07-14-2009, 02:17 AM
got the door panel cut out today. put it on the door and it fits its just kinda a weird fit. it wobbles on the door and doesnt go flat. any suggestions? also where do i go from here? do i make little trim peices for the whole panel? kinda stuck for right now.

basscort2009
07-14-2009, 02:32 AM
maybe i could clamp the top and bottom of the 3/8 plywood to make it bend a little and then resin it a couple times before releasing the clamps, thus holding a curved peice of resined plywood???

let me know if this is epic failure waiting to happen. i really need some suggestions

Nut Hair Trick
07-14-2009, 02:45 AM
maybe i could clamp the top and bottom of the 3/8 plywood to make it bend a little and then resin it a couple times before releasing the clamps, thus holding a curved peice of resined plywood???

let me know if this is epic failure waiting to happen. i really need some suggestions

Let me just say that I'm still new to glassing and working with wood. But, an image popped into my head when you mentioned clamping the wood and then resining. Have you ever seen people make like kerf cuts for ports? You might could do something similar, clamp, then resin so it takes the shape of the door. Just a thought I figured I would throw out there. May work, might not. Good Luck.

SWFL
07-14-2009, 02:53 AM
pics?

ramos
07-14-2009, 08:23 AM
^ x 2 would make suggestions easier :)

tylork92
07-14-2009, 08:26 AM
pics would help drastically.....but theres probably pieces preventing it to go flat on the door...and those pieces are probably makin scuffs on the back piece of wood so just use a dremel to grind out those spots to let it fit snug to the panel.

basscort2009
07-14-2009, 10:23 AM
pics would help drastically.....but theres probably pieces preventing it to go flat on the door...and those pieces are probably makin scuffs on the back piece of wood so just use a dremel to grind out those spots to let it fit snug to the panel.

ill upload the pics later today, but i cant use a dremal as the peice of ply is only 3/8 thick and it is not thick enough to do that method :crap:

ramos
07-14-2009, 10:26 AM
Take some pics with and without your panel in place. I have a few ideas, but pics would better help send you down the easiest most durable path :)

WrenchGuy
07-14-2009, 10:27 AM
I kinda have the same issue.

My cure was to put the wood to the door and drill a hole through both. Puta nut and bolt on wood side (countersunk) and put the bolt through the hole in the door. Using the speaker hole as access put a nut on the bolt inside the door and tighten.

basscort2009
07-14-2009, 01:53 PM
I kinda have the same issue.

My cure was to put the wood to the door and drill a hole through both. Puta nut and bolt on wood side (countersunk) and put the bolt through the hole in the door. Using the speaker hole as access put a nut on the bolt inside the door and tighten.

i may try that as well.

and as for pics my computer doesnt have a slot for a memory card that the cameras use. so ill have to go to my inlaws sometime and get them

basscort2009
07-14-2009, 01:56 PM
actually just took some with my phone so ill post them in a minute and see if yall can tell me by those

basscort2009
07-14-2009, 02:37 PM
PICS!!!!!

WITH PANEL OFF
http://i65.photobucket.com/albums/h236/basketball3rulz/bg.jpg

WITH PANEL ON
http://i65.photobucket.com/albums/h236/basketball3rulz/asd.jpg

GAP BETWEEN PANEL
http://i65.photobucket.com/albums/h236/basketball3rulz/dfg.jpg

ramos
07-14-2009, 02:39 PM
So is the only gap at the top of the panel? Your going to need some kind of weather stripping for a seal against the window. :)

WrenchGuy
07-14-2009, 03:52 PM
Its hard too see but could you just cut and staple the original part of the panel to the wood that butts the window? Or is that wood out too far?

Again old monitor hard to see...lol

ramos
07-14-2009, 03:54 PM
Its hard too see but could you just cut and staple the original part of the panel to the wood that butts the window? Or is that wood out too far?

Again old monitor hard to see...lol

That's the way it looks to me. Like the gap he is talking about is from the missing weatherstip from the oem panel. :)

basscort2009
07-14-2009, 07:19 PM
That's the way it looks to me. Like the gap he is talking about is from the missing weatherstip from the oem panel. :)

no that gap is with the bottom flush against the panel. like i said earlier it rocks back and forth and it doesnt sit flat :/ and yea i was thinking about doing the old panel trim part but how would i cover that in the end of the project? i wanted to do vynil but not if i have to go over a busted trim panel from a busted door panel.

thanks for all the help so far guys

basscort2009
07-14-2009, 10:34 PM
no one else?

basscort2009
07-15-2009, 11:33 AM
still need some help guys

ramos
07-15-2009, 12:19 PM
Does your panel sit flush everywhere else but that gap at the top? That's the way most oem door panels are designed, so that the top weatherstrip helps "hang" the door card( panel) on the metal door itself. :)

basscort2009
07-15-2009, 12:23 PM
yea its mostly flush everywhere else. not as flush as a regular door panel cuz its flat and doesnt have the curves on the edge all the way around like regualr door panels

gnatnoop
07-15-2009, 07:48 PM
i didnt read thread just op and looked for pics, but if you just want it to stay on the door (flush) use screws and liquid nails... however it would be much easier to fiberglass first...

basscort2009
07-15-2009, 08:08 PM
i didnt read thread just op and looked for pics, but if you just want it to stay on the door (flush) use screws and liquid nails... however it would be much easier to fiberglass first...

:wow: i would never be able to get it off if i liquid nailed it. i just need an idea for a trim peice to go over the top of the panel

basscort2009
07-15-2009, 10:59 PM
anyone else?

basscort2009
07-16-2009, 09:03 PM
bump

basscort2009
07-17-2009, 02:51 AM
bump