Custom door panels, CAD/CNC
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Cargo Master
Joined: Sep 2007
Posts: 2,470
Likes: 535
From: Chandler, AZ
Custom door panels, CAD/CNC
Made some new door panels for my 72 F250. Didn't want to use any wood or pressboard, instead aluminum and foam. Style is similar to the original.
Step one was to locate all the features and make a template in CAD. I use fusion 360.
Base panel cut on CNC plasma
test fit on door to make sure all 15 clips line up.
Insert panel cut out of aluminum. Transfer holes from previous CAD drawing.
Insert wrapped in diamond stich same as seat.
I decided I needed 3/8 of foam to match wrapped insert. So two layers of 3/16 I could buy locally.
Swapped plasma torch for a cheap die grinder with a plunge bit to cut foam in CNC table.
Glued foam to aluminum, and wrapped in vinyl.
Used some adhesive tape to secure panel ends, but arm rest and door cup hold it to the door.
I used plastic 'christmas tree' clips instead of the metal ones. Cut a keyhole for them.
Second door was quick, just press button to cut out the pieces.
Also wrapped the dash
Step one was to locate all the features and make a template in CAD. I use fusion 360.
Base panel cut on CNC plasma
test fit on door to make sure all 15 clips line up.
Insert panel cut out of aluminum. Transfer holes from previous CAD drawing.
Insert wrapped in diamond stich same as seat.
I decided I needed 3/8 of foam to match wrapped insert. So two layers of 3/16 I could buy locally.
Swapped plasma torch for a cheap die grinder with a plunge bit to cut foam in CNC table.
Glued foam to aluminum, and wrapped in vinyl.
Used some adhesive tape to secure panel ends, but arm rest and door cup hold it to the door.
I used plastic 'christmas tree' clips instead of the metal ones. Cut a keyhole for them.
Second door was quick, just press button to cut out the pieces.
Also wrapped the dash
Logistics Pro
Joined: Jun 2003
Posts: 3,924
Likes: 273
Very nice. You don't need the 15 clips around the edge if using aluminum instead of fiberboard. I did the same thing and then realized I didn't need all the clips. I think the factory did this because they knew the fiberboard would flex and warp.
Lead Driver
Joined: Jul 2017
Posts: 9,601
Likes: 1,174
From: San Jose, CA
Great product!
Now all you need to do is add map pockets for the win! 😁😉😎
We’ll, that and maybe some sound deadening to the backside?
Now all you need to do is add map pockets for the win! 😁😉😎
We’ll, that and maybe some sound deadening to the backside?
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Cargo Master
Joined: Sep 2007
Posts: 2,470
Likes: 535
From: Chandler, AZ
The doors already have sound deadening mat on the skin so no need on the panels.
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