Jon Mc V6`
19-09-2005, 07:59 PM
Before you start this make sure you have considered the following points:
There are some complex curves to stretch the material around so ensure that your material has some elasticity.
Buy following my instructions the finish can be changed, but not returned to it's original state, so make sure you are sure.
STEP 1.
Remove and completely strip your doorcards. You then need to make a template for the insert. By using cardboard you can make one, but what I did was cut out the old material and used that as my template.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0014.jpg
STEP 2.
Using the template you have made make a doorcard insert using hardboard. Make the doorcard insert slightly oversize as it is easier to trim it than it is to add to it.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0019.jpg
STEP 3.
Once you have made your doorcard insert, lay it out on your material. Ensuring that you have an overlap of about one inch cut out your material. At this stage I also added a layer of thin foam. This should be cut to the same size as the doorcard insert, without any overlap. Here is where you have to make your first choice. Once the material is ready to be attached you have to either glue or staple it. Once glued it is difficult to change, and quite difficult with the amount of stretching and straining you are going to put on the material. Obviously you could clamp the material in place, but with suedette or alcantara you will mark the material. I used a staple gun with some short (5mm iirc) staples and stapled all around the overlap, stretching the material around the insert as I went. If you use glue my advice would be to glue the material to the front of the insert, let it dry and then glue the overlap. Make sure you round the edges of the hardboard for a better finish.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0015.jpg
STEP 4.
Choice number 2, glue or self tappers. Now your doorcard inserts should be complete, and you can attach them to the doorcard with impact adhesive or carpet glue. imho this is not as secure as screws, especially when the car gets hot the glue may weaken. Again, the way I did it was with some 8mm mushroom head self tappers. These screw through the doorcard into the insert without comming out the other side (or at least that is the case with the extra foam layer). It also means the inserts can be removed and re-trimmed (or used for a How2) at any time.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0013.jpg
STEP 5
Reassemble your doorcard and refit ot the door. (Ignore the colours of the trim items as it is a 'work in progress')
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0010.jpg
For ideas of other colours you should be able to photoshop these pics if you have photoshop, I'm afraid I don't.
Lessons I learned the hard way:
Don't use cardboard (no matter how heavy duty) to make the inserts.
IMHO don't glue the inserts in place, it's messy and a pain to redo.
Make sure you material has some flexibility, if it doesn't the finished job will split where you trim it for the complex curves, crease and buckle around these curves and look cheap.
Obviously I did this on a cavalier, but the same technique can be used on most cars. Any q's please fire away.
There are some complex curves to stretch the material around so ensure that your material has some elasticity.
Buy following my instructions the finish can be changed, but not returned to it's original state, so make sure you are sure.
STEP 1.
Remove and completely strip your doorcards. You then need to make a template for the insert. By using cardboard you can make one, but what I did was cut out the old material and used that as my template.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0014.jpg
STEP 2.
Using the template you have made make a doorcard insert using hardboard. Make the doorcard insert slightly oversize as it is easier to trim it than it is to add to it.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0019.jpg
STEP 3.
Once you have made your doorcard insert, lay it out on your material. Ensuring that you have an overlap of about one inch cut out your material. At this stage I also added a layer of thin foam. This should be cut to the same size as the doorcard insert, without any overlap. Here is where you have to make your first choice. Once the material is ready to be attached you have to either glue or staple it. Once glued it is difficult to change, and quite difficult with the amount of stretching and straining you are going to put on the material. Obviously you could clamp the material in place, but with suedette or alcantara you will mark the material. I used a staple gun with some short (5mm iirc) staples and stapled all around the overlap, stretching the material around the insert as I went. If you use glue my advice would be to glue the material to the front of the insert, let it dry and then glue the overlap. Make sure you round the edges of the hardboard for a better finish.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0015.jpg
STEP 4.
Choice number 2, glue or self tappers. Now your doorcard inserts should be complete, and you can attach them to the doorcard with impact adhesive or carpet glue. imho this is not as secure as screws, especially when the car gets hot the glue may weaken. Again, the way I did it was with some 8mm mushroom head self tappers. These screw through the doorcard into the insert without comming out the other side (or at least that is the case with the extra foam layer). It also means the inserts can be removed and re-trimmed (or used for a How2) at any time.
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0013.jpg
STEP 5
Reassemble your doorcard and refit ot the door. (Ignore the colours of the trim items as it is a 'work in progress')
http://img.photobucket.com/albums/v521/jonmcv6/2005_0918Image0010.jpg
For ideas of other colours you should be able to photoshop these pics if you have photoshop, I'm afraid I don't.
Lessons I learned the hard way:
Don't use cardboard (no matter how heavy duty) to make the inserts.
IMHO don't glue the inserts in place, it's messy and a pain to redo.
Make sure you material has some flexibility, if it doesn't the finished job will split where you trim it for the complex curves, crease and buckle around these curves and look cheap.
Obviously I did this on a cavalier, but the same technique can be used on most cars. Any q's please fire away.