A Dumb Door Panel Question
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
A Dumb Door Panel Question
How complex are door panels in their shape? I mean on the back side.
If I pull my ratty old inner door panels, will the surface I find be simple enough that a guy who wanted something different might be moved to make his own door panels?
Or do the panels have to conform to a lot more than a flat surface with a couple of openings in it?
Lane
If I pull my ratty old inner door panels, will the surface I find be simple enough that a guy who wanted something different might be moved to make his own door panels?
Or do the panels have to conform to a lot more than a flat surface with a couple of openings in it?
Lane
Post Fiend
Joined: Jul 2003
Posts: 11,945
Likes: 3
From: Spokane, WA
Yes, the door surface is "basically" flat. One of my bling thoughts was to use diamond plate aluminum for a door panel. It would be simple to do, just cut a template using the stock panel and then add an arm rest, cut holes for the window crank and door handle. The actual handle of the door would stick out goofy though so that would be something I'd replace with a flatter looking handle. But in any event you should be able to use any flat material to create a new panel.
Posting Guru
Joined: Jun 1999
Posts: 1,172
Likes: 2
From: SW Missouri
early 70s car door panels can be used for their armrests and handles etc. I took 1/4 plywood, routed the edges, and covered it with thin foam, and cloth. you can layer the foam, or even layer the wood under the foam to make it more textured. the window cranks stick out quite a bit, so layering here is a good idea. I'm tempted to sell my extra sets of rear door panels, and make custom ones or add power windows.
I had a set of add-on power windows that attached to the existing cranks, and then hid them in a big armrest on one truck, but I think I'll try to make real power window mechanisms with a passenger car set, or newer truck set this time.
I had a set of add-on power windows that attached to the existing cranks, and then hid them in a big armrest on one truck, but I think I'll try to make real power window mechanisms with a passenger car set, or newer truck set this time.
Elder User
Joined: Oct 2004
Posts: 527
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From: Port Alberni
i made some real nice 1/2 wooden door panels the only problem i had was to cut the back half of the door handle then you can make a headliner from 1/8 door skins and stain them any way youwant looked good in my truck '
Thread Starter
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
LOL!
Hey, that's the first thing I was thinking of: Aluminum diamond plate. 
I figured that would be good for a macho work truck. Then I got to thinking about some hardwood veneer or maybe even covering part of it with leather.
There are some great ideas here.
With those replacement plastic door panels being 100 bucks or more, I thought it might be worth a little time to come up with something different. Heck, maybe even build in a feature or two: a hidden compartment for change and such, or a bracket and/or sheath for your machete or hatchet (OK, I'm out in the woods a lot and it really is a work truck
), little courtesy lights in the lower panel like the more modern rigs...
Thanks for the good ideas.
Lane
Hey, that's the first thing I was thinking of: Aluminum diamond plate. I figured that would be good for a macho work truck. Then I got to thinking about some hardwood veneer or maybe even covering part of it with leather. There are some great ideas here.
With those replacement plastic door panels being 100 bucks or more, I thought it might be worth a little time to come up with something different. Heck, maybe even build in a feature or two: a hidden compartment for change and such, or a bracket and/or sheath for your machete or hatchet (OK, I'm out in the woods a lot and it really is a work truck ), little courtesy lights in the lower panel like the more modern rigs... Thanks for the good ideas.
Lane
Posting Guru
Joined: Jun 1999
Posts: 1,172
Likes: 2
From: SW Missouri
with what peopel are willing to pay for rear door panels, I'm almost sure to make my own, and sell the OEM ones I have.
I was thinking of making a better armrest, with large lower map pockets like in my 97 Powerstrokes. a courtesy light/red reflectorcombo from a 70's car woudl fit and look OEM.
I was thinking of making a better armrest, with large lower map pockets like in my 97 Powerstrokes. a courtesy light/red reflectorcombo from a 70's car woudl fit and look OEM.
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Posting Guru
Joined: Jun 1999
Posts: 1,172
Likes: 2
From: SW Missouri
I think 73-78 full size ford armrests with the deluxe interiors would work to cover the window cranks to allow for add-on power windows, they use similar door handle mechanisms, and have padded tops. might work for what some of you want.
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Senior User
Joined: Apr 2004
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The only thing with wooden door panels is safety - wood was pretty much banished from modern vehicles because in an accident it splinters, creating sharp edges and projectiles. A side-impact on a door with wood panels could do serious damage to the person beside it...
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
I appreciate the warning. I was thinking only of thin plywood paneling, if one decided to go that way for the appearance. Personally, I'm leaning more toward the diamondplate for a work truck.
Posting Guru
Joined: Feb 2002
Posts: 2,404
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From: Cleveland, WI USA
I used a thin piece of masonite and made panels for my doors. I got rid of the arm rest and just put a pull handle near the top. I drilled a hole for the window crank and two where the armrest used to bolt on. Used the armrest bolts to hold the center on and self tapping screws around the edge.
I had to make a new door handle because of how far the stock one sticks out without the arm rest. Here's what it looks like.
I like the diamond plate idea, too.
K.
I had to make a new door handle because of how far the stock one sticks out without the arm rest. Here's what it looks like.
I like the diamond plate idea, too.
K.
Thread Starter
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Laughing Gas
Joined: Aug 2004
Posts: 1,249
Likes: 2
From: Rockport, WA
Couldn't get the picture, just a little red X. I looked at your gallery, but didn't see it. Server seems busy. But I get the idea. Flat homebuilt door panels are feasible, you'll just want to shorten the door handle.
Thing is diamond plate will still cost about $100 for a pair, but they'd look killer and last forever.
Oh well, maybe I can "find" some leftover diamond plate somewhere....
Senior User
Joined: Jul 2004
Posts: 407
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From: ct.
I've seen a few homemade diamond plate panels at some shows. They look great. If I was going to make some up that would be my choice. Shop around for the aluminum. Prices differ greatly from place to place. I bought a 4'x8' sheet a few years ago and used it up as I needed it. Love that shiny stuff. Very pricy though.