I don't like the door panels in my car because they are terrible, plus they had to go to make room for the roll cage. Here is my journey:
Started here with a modified T2 panel for window roller duty. has a hole cut in it due to the door not unlocking one time lol.
Everything must go!
Rivenuts for attaching the cards.
A crushed one. Basically they just clamp the material like a rivet. They are very secure if installed properly.
I used a piece of acrylic (Plexiglass) for the door card template, because it's cheap and transparent.
Temporary hardware for fitting. Yes my temporary hardware is stainless steel. I told you I have a problem
Cut the template up some more. The band saw works pretty good on this stuff. Oh I forgot to mention the sunroof is Lexan (Polycarbonate) not Acrylic. You'd have to have a death wish to use Acrylic there. If it shatters which it probably would it could saw your head off. No biggie, moving on.
Attempting to get the door release handle hole situated.
Window roller hole looks about right.
Giant piece of aluminium for the actual door cards. I was originally going to use ABS plastic but then I remembered I didn't want to be sliced to pieces if it shattered so I didn't.
The next bunch of pics were off my cell phone because the camera battery died, sorry.
Here's a nearly finished door card fitted.
Then I was coming up with possible door handle pull options. this ones pretty simple and very sturdy. I may go with it, but I still haven't decided yet.
The passenger door is super easy because the template is already made. Punched out the factory clip holes to the size for the rivenuts, bolted up the template, marked the other holes. drilled those, put the rest of the rivenuts in. Boom! done.
Passenger door just before drilling the second set of holes. Also all this gooey black stuff needs to be removed so I can repaint the door. Plus I don't want it to get all over everything.
