A Dumb Door Panel Question
Post Fiend
Joined: Jul 2003
Posts: 11,945
Likes: 3
From: Spokane, WA
Well I've got a line on some sheets of that aluminum, right about the correct size too for only $30 a piece but then it costs another $20 per sheet to ship. 
They certainly don't give the stuff away.
They certainly don't give the stuff away.
Senior User
Joined: Jul 2004
Posts: 407
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From: ct.
While walking through Home Depot one day last week I noticed they had what I thought were 2'x2' pieces of diamond plate. Didn't look at price or exact size of pieces but thought if I ever needed any small sizes I would have to remember to go back there. Just a thought.
Post Fiend
Joined: Jul 2003
Posts: 11,945
Likes: 3
From: Spokane, WA
I buy all my diamond plating from an ebay seller by the name of "cutsmetal". Their prices are excellent, literally half of what you'll pay at Home Depot or Lowe's. They have decent shipping rates too. I just got an e-mail back for .063 thick diamond plate aluminum it would be $27 for a 24x36 sheet (what you'll need for a door panel, with a little extra) and $14 to ship. Only $2 to ship a second sheet with that. So for $70 you could have the material, not counting arm rests and all that nonsense.
Posting Guru
Joined: Jul 2001
Posts: 1,613
Likes: 2
From: Gainesville, FL
All,
Did someone say "CHEAP".
Go to Home depot.
Buy some panel board.
Find the material of choice: leather, vinyl, whatever.
A map box can be fabricated from a box and glued to the pegboard.Coat it with your material of choice. I glue my material on with 3M 77 superhold. You could give your panel some depth with styrofoam or some other material that is easily shaved. If you want a smooth look you'll have to fasten your fasteners to the back of the panel. If you want vintage look, get some stainless steel screws with dress washers and screw it to the door. The peg board is pretty easy to cut and can be shaped when wetted. I've used this technique on vintage restorations and fooled the judges.
Believe it or not,
KingFisher
Did someone say "CHEAP".
Go to Home depot.
Buy some panel board.
Find the material of choice: leather, vinyl, whatever.
A map box can be fabricated from a box and glued to the pegboard.Coat it with your material of choice. I glue my material on with 3M 77 superhold. You could give your panel some depth with styrofoam or some other material that is easily shaved. If you want a smooth look you'll have to fasten your fasteners to the back of the panel. If you want vintage look, get some stainless steel screws with dress washers and screw it to the door. The peg board is pretty easy to cut and can be shaped when wetted. I've used this technique on vintage restorations and fooled the judges.
Believe it or not,
KingFisher
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
"Cheap" I like! I can identify with that! And, come to think of it, a lot of those old car inner door panels really were not much more than cardboard with vinyl over it. I'm getting some good ideas here! Thanks.
Posting Legend
Joined: Sep 2001
Posts: 30,255
Likes: 37
You can also buy "Kydex" sheet ABS plastic from plastic supply houses. You can get it in many thicknesses and colors. I think about .090" or 3/32" would work good for a door panel. You can even vacuum form the material if you want to.
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
Hey, that's a thought! I know some real Kydex wizards. I'll see Brian Wagner of Okuden and possibly Tim Wegner of Blade Tech tomorrow, when I go to a Washington Arms Collectors show in Puyallup. Those guys really know how to make sheaths, holsters and such from Kydex. Neat material!
Post Fiend
Joined: Jul 2003
Posts: 11,945
Likes: 3
From: Spokane, WA
Hmm . . . a gun holster molded into your door panel. THAT's something I'd like to see in a truck. 
Good thinking Torque! I've never seen plane old sheets of Kydex for sale . . . going to have to take a look now.
Good thinking Torque! I've never seen plane old sheets of Kydex for sale . . . going to have to take a look now.
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
Hey, kjkozak2, the picture came up today! I like your horseshoe door handle. I couldn't see it before.
And now, ivanribic, I'm back to thinking about holsters and sheaths on the door.
Some pickups have the space, and there have been brackets/racks made, to carry a hunting rifle at a muzzle down slant on the door.
I was thinking more in terms of keeping your most frequently used outdoor tool -- be it hatchet, cruiser's axe or machete, handy on the door.
Well, I'll undoubtedly be talking to Brian Wagner of Okuden tomorrow. I'll ask about Kydex prices and machete sheath prices. If it's prohibitively expensive, I'll go back to thinking about wood (rigid sheath for safety) or heavy leather. Just make the door panel of whatever material is handy and affordable, then rivet on your sheath of choice.
Lane
I couldn't see it before. And now, ivanribic, I'm back to thinking about holsters and sheaths on the door.
Some pickups have the space, and there have been brackets/racks made, to carry a hunting rifle at a muzzle down slant on the door. I was thinking more in terms of keeping your most frequently used outdoor tool -- be it hatchet, cruiser's axe or machete, handy on the door. Well, I'll undoubtedly be talking to Brian Wagner of Okuden tomorrow. I'll ask about Kydex prices and machete sheath prices. If it's prohibitively expensive, I'll go back to thinking about wood (rigid sheath for safety) or heavy leather. Just make the door panel of whatever material is handy and affordable, then rivet on your sheath of choice.
Lane
New User
Joined: Dec 2004
Posts: 23
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I was wondering what a sheet metal guy could do. I wanted to have some made for my '67 (they are all metal). One of the previous owners cut holes for speakers. Looked like they used a dull butter knife. Needless to say, it was all hacked up. I sold the truck before I got them made. My understanding is that real sheetmetal shops have all the tools to roll the edges and put the creases and dents in the middle, including holes for door handles, etc... I never did price it. I wonder what they could do to copy something to work with the newer trucks with plastic door pannles. I also found this stuff that is a sticker that looks a awful lot like diamond plate. It looks pretty realistic, util you get right up to it and touch it.
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
I think you're onto something. The door panel on 73-79 trucks isn't all that complex a shape. I'm still thinking about diamond plate for mine. I have my eye on a scrap of 1/8" aluminum. 
I did recently make a wood (oak) sheath for an old machete. If I was a really talented woodworker (I'm not), I'd think about wood panels. The acoustics would be better, even if the durability wasn't.
I did recently make a wood (oak) sheath for an old machete. If I was a really talented woodworker (I'm not), I'd think about wood panels. The acoustics would be better, even if the durability wasn't.
New User
Joined: Dec 2004
Posts: 7
Likes: 0
From: Fort Worth, Texas
As far as having a sheet metal guy amke the door panels, find a stainless steel fabricator. They are really magical with that stuff, can make seams disappear and make it look like it was stamped if they know what they are doing. My thoughts
Posting Guru
Joined: Jan 2005
Posts: 1,749
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how about
how about you ambitious folks make some extras and sell them on ebay? I can't STAND door panels in these series of trucks.. i wanna buy new ones, but I can't spend $80 on a cheap piece of plastic that breaks if I look at it wrong.
so build some and throw them on ebay. Put some modified door handles, wondow cranks (just add some kinda rubber boot to the area extended to the window crank, would look nice). Heavy *** doors being pulled shut all the time by a thin piece of plastic just isn't right.. and it shows on just about all trucks in this series.
yea. I'm willing to pay $80 for a decent door panel.
i'd do it myself but I'm not good at cutting straight edges.
I really can't believe noone else has made replacement panels for these trucks..
so build some and throw them on ebay. Put some modified door handles, wondow cranks (just add some kinda rubber boot to the area extended to the window crank, would look nice). Heavy *** doors being pulled shut all the time by a thin piece of plastic just isn't right.. and it shows on just about all trucks in this series.
yea. I'm willing to pay $80 for a decent door panel.
i'd do it myself but I'm not good at cutting straight edges.
I really can't believe noone else has made replacement panels for these trucks..
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