aerostar door panels
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New User
Joined: Nov 2012
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aerostar door panels
Im new to the forum and have a 96 extended aerostar. My question ia has any one made custom front interior door panels. Mine are badly broken up and I feel beyond repair. Thanks Curt
Laughing Gas
Joined: Jun 2004
Posts: 1,240
Likes: 3
From: Dallas, Texas
Your best bet is the salvage yard. They are all black plastic with the cover stapled on and a little glue on the bottom. If its not bad you can use a soldering iron to weld the cracks and loose parts back. I found that option works great.
Postmaster
Joined: Oct 2009
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The best solution if they are not too far gone is to repair them from the back using resin and fiberglass. You first fill the cracks with the resin to bond the joint, then you apply fiberglass sheets and resin to the back of the panel. This adds some extra strength to reinforce the repair. An additional step is to take some great stuff expanding foam and fill the weak areas with that. Once the foam sets you can cut it flush with the back of the panel. This adds extra strength and sound deadening without adding a lot of extra weight.
I do think a new replacement part would be wonderful, but probably not enough demand to justify getting the molds made.
I do think a new replacement part would be wonderful, but probably not enough demand to justify getting the molds made.
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New User
Joined: Nov 2012
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door panels
the originals are badly broken up with several cracks in both. I am thinking of a piece of diamond plate and a universal arm rest, but I dont know how flat the door frame is to screw it to the frame. Thanks
Fleet Mechanic
Joined: Apr 2003
Posts: 1,460
Likes: 6
From: Florida
The best solution if they are not too far gone is to repair them from the back using resin and fiberglass. You first fill the cracks with the resin to bond the joint, then you apply fiberglass sheets and resin to the back of the panel. This adds some extra strength to reinforce the repair. An additional step is to take some great stuff expanding foam and fill the weak areas with that. Once the foam sets you can cut it flush with the back of the panel. This adds extra strength and sound deadening without adding a lot of extra weight. I do think a new replacement part would be wonderful, but probably not enough demand to justify getting the molds made.
Laughing Gas
Joined: Jun 2004
Posts: 1,240
Likes: 3
From: Dallas, Texas
They make a iron and glue just for plastic welding and its been approved by all the insurance companys for repairing all kinds of plastic ABS etc.
Youtube has many videos on it, you might check them out.
Youtube has many videos on it, you might check them out.
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