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So I can’t leave anything well enough alone and while I have a thread for the build out of my truck I thought some might find it more interesting to tack just the door cards build out. I’ll be cross posting in both but there will be more details here.
I started with a plan to come up with something that I can replicate if others are interested. Also I am making digital files for everything and will have them available too.
first off I don’t care to much for all the reproduction panels and the fat fenders are everywhere and cost an arm and a leg. So, here we are.
First off… rough measurements.
not the best but it’s a start.
Next step, get them onto the computer to cad them out.
it took a while but with the image as a baseline I could measure against the door and set the points on the photo and mark out each location and cross reference points from multiple measurements.
I got a little side tracked and started making up some speaker grills too. I haven’t decided one one yet but who knows maybe I’ll come up with something more.
Lots of fun. I put new doors on and decided to make my own interior panels, and since I was gonna pitch my OEM doors, I took a saw and cut the inside of the driver door out and soon had it in my shop on a table and commenced to measure. I made my inners in three sections so the center piece was independently removable, for servicing the glass, etc .... and the top and bottom stay put. I used my notes to create this "chart" for my reference. If you can use it, you are welcome to it. You might want to blow it up though? My originals were ready for a change out.
Using these notes, mine came out good if I say so myself.
I like your script style Ford speaker grills. I might even have to make a couple using a map of Texas now.
Last edited by tbear853; Nov 24, 2025 at 11:40 PM.
Using these notes, mine came out good if I say so myself.
I like your script style Ford speaker grills. I might even have to make a couple using a map of Texas now.
thank you sir, I can mock some up for you if you’d like in an svg or whatever file you need.
I’ll cross reference my measurements to yours to see if anything is grossly incorrect.
im going to cut a template from some scrap 1/8” and see where it sits.
Post up the link to your build or pm me some photos, I’d like to see how you did the three pieces.
thank you sir, I can mock some up for you if you’d like in an svg or whatever file you need.
I’ll cross reference my measurements to yours to see if anything is grossly incorrect.
im going to cut a template from some scrap 1/8” and see where it sits.
Post up the link to your build or pm me some photos, I’d like to see how you did the three pieces.
Well, it is a thread where I made changes as I went along. Was a lot of ideas from others in that thread too.
I wanted a Texas theme, so the reflective red / white / blue stretched look flags on polished aluminum trim .... and I wanted my console to look like it blended. Once the decision is made to get away from factory molded panels, the options expand / evolve. I know there are pictures in the thread, but here below is how they are right now as I post this. I thought about, and can still .... revert to black 1/4-20 socket head screws but I'm good with SS. My panels have a plastic back side as a vapor barrier.
Wife had some napkins in the pockets, but they do show height of pocket in relation to seat height. Mercury GM seats.
Last edited by tbear853; Nov 25, 2025 at 11:25 AM.
I wanted a Texas theme, so the reflective red / white / blue stretched look flags on polished aluminum trim .... and I wanted my console to look like it blended. Once the decision is made to get away from factory molded panels, the options expand / evolve. I know there are pictures in the thread, but here below is how they are right now as I post this. I thought about, and can still .... revert to black 1/4-20 socket head screws but I'm good with SS. My panels have a plastic back side as a vapor barrier.
Wife had some napkins in the pockets, but they do show height of pocket in relation to seat height. Mercury GM seats.
Those look really nice! I'll be looking myself to do this in a couple months and will definitely be referencing both of y'all's information.
Those look really nice! I'll be looking myself to do this in a couple months and will definitely be referencing both of y'all's information.
I should have all the files complete by then. My goal is to create a doc, svg, pdf and a reference file with measurements that can be printed full size at a document center to use as a template too. Ideally anyone could then print it and have a ready to go template to use to make their own.
or possibly I’ll just start making door panels as a side gig…
Andy Rooney once wrote of an experience in England during WWII when he was a war correspondent, on a bomber base. One evening he tagged along with some of the guys going into town, exploring. They stopped to watch a blacksmith working at his forge. They saw that he would ... ever so often between heating ups and hammer blows ... hold the item in his tongs and hold it up to the better light to look. It interested the group.
One of the boys in the group said "Shoot, that ain't nothing, Why we have machines back home that will make that to within a thousandth of an inch accuracy"
to which the old blacksmith just spit his chew, and said "That might be alight back home, but over here, it has to be spot on"
Last edited by tbear853; Nov 27, 2025 at 07:54 PM.
Andy Rooney once wrote of an experience in England during WWII when he was a war correspondent, on a bomber base. One evening he tagged along with some of the guys going into town, exploring. They stopped to watch a blacksmith working at his forge. They saw that he would ... ever so often between heating ups and hammer blows ... hold the item in his tongs and hold it up to the better light to look. It interested the group.
One of the boys in the group said "Shoot, that ain't nothing, Why we have machines back home that will make that to within a thousandth of an inch accuracy"
to which the old blacksmith just spit his chew, and said "That might be alight back home, but over here, it has to be spot on"
A lot of truth in that. You’ll enjoy following along this project. Just you wait.
Have some time to work on the door cards a little bit more and I have to say I like the way they are turning out.
I went to FB marketplace to find some material and had some success. I found some almost 3/8 inch hardboard with some kind of a waterproof backing on one side. Seems perfect for the job.
I also found a 2” x 4” x 12” piece of square aluminum tubing that I will be cutting into L brackets two create the armrest supports.
Here is the latest variation of the door card that I’m working on. I may need to go thicker on the surround and speaker surround in order to get the correct clearance for the 6 1/2 inch component speaker woofer.
i’d appreciate any feedback you guys have on building these out. I’m hoping to avoid making too many mistakes along the way.
Looking good on them custom panels. Just remember that there 2 TWO different length of door handles, different length at the part that goes over the regulator splines. The short version for plain plastic door panels and the long version for when you have the XLT vinly over lay door panels. So you migth have to source the longer ones depending on your finial design. I am out of the long ones at the moment. T bear you might benifit also.
Looking good on them custom panels. Just remember that there 2 TWO different length of door handles, different length at the part that goes over the regulator splines. The short version for plain plastic door panels and the long version for when you have the XLT vinly over lay door panels. So you migth have to source the longer ones depending on your finial design. I am out of the long ones at the moment. T bear you might benifit also.
I might even have to make a couple using a map of Texas now.
