a few weeks ago I finally decided to tackle repairing the door clip ( aka Christmas tree fasteners) retainer tabs on the inside of my door panel. I did this with a very clean 40-watt soldering iron, and a broken ashtray that was of the same plastic (color shouldn't matter). I repaired around 6 of the tabs. This is similar to plastic welding, in that it melts the plastic filler in with heat. This repair seems to hold up well. Plastic needs to be clean of dirt and grime before the filler material is melted on. I also added a fender washer in the armrest to help spread the load when a person pulls on it to shut the door.

*feel free to use a plastic welder kit or epoxy, if you do not trust this method. I happened to try this since the panel was in good shape otherwise, and it seems to work well.

 

All of those clips broke off each of my door panels before I even bought the truck (had it two years now). The p/o just dealt with the panels being flimsy, but I hated it. I don't really care about how the interior of my truck looks, as long as it works I don't mind. So I just ran self tapping sheet metals screws through the door panel into the door. Holds on tight, and you don't even really notice the screws.

I hate those little plastic clips.

 

I couldn't bring myself to do that to a panel that was other wise in really good shape. it had been lose for the last 2 years.

 

this didn't last over a month. even with the new clips and tabs, the panel kept working loose. tried a black interior screw, worked perfect until the screw worked loose. may have to use a rivnut in the door shell, and a 10-24 black screw. Not ideal, but for whatever reason the door clips dont hold it tight. Also need to repair where a piece broke off that the scraper seal clips on.

 

Thanks for the update

 

My next plastic repair attempt will be screen shaped to the part(s) possibly plastic welded & then layered with epoxy to build structure.

I've done a couple of dash tabs, (low stress) backed with about 10 gauge bailing wire, washers & epoxy with good results.

 

I have had good luck repairing plastic parts with fiberglass. I use the resin with the hairs in it and mix like bondo. It sticks well to the plastic if you rough it up. The epoxy doesn't still as good I have noticed.

 

Get the x-mas tree mounts 3d printed, rough up both parts, adhere them using a two parts epoxy like 3M 8115 mixed with some fiberglass flox and it will work. Ive also used gorilla glue ultra 2 part epoxy and fiberglass to rebuild strength and repair panels.

YMMV.

 

Thought about using the door clip retainer tabs off an old damaged grey door panel, cut them off, and use lots of jb weld and possibly some fiberglass to reinforce It. the hair line crack in the top of the door panel has gotten worse, so I'll have to repair that too while its off. Probably until I can find some nicer door panels. I see some like these for $200- 350 a set on ebay, with broken tabs, no thanks...

 

Too bad you're not down in the Texas area. IIRC LKQ is a nationwide company, Im fairly familiar with the Pick-a-Parts, so many Fords to pull panels from.

 

I keep an eye out at the local LKQ for interior panels.

 

gave it another shot, roughed up the areas with 40 grit, cut tabs off another door, and used jb quick weld.