Cutting openings in Door Panels

[randywebb]

I ordered some new door panels from Sewfine but they did not cut out any of the vinyl for the openings where the window crank, door pull, etc. go (despite my asking them to do so).

I am wondering if it is better to cut the vinyl flush with the cutouts they did make in the masonite (like the stock panels have)?

Or I could cut an "X" and then fold the vinyl around to the back of the masonite...

Anyone tried different methods?
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1986 2.1L Westy 2wd Auto Trans.

[insyncro]

Is the vinyl glued in place around the location for each hole?

[randywebb]

hard to tell thru the back of the vinyl, but I think so
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1986 2.1L Westy 2wd Auto Trans.

[furrylittleotter]

I'd cut an "X", fold it in and glue it in. Please post pics and prices on project if you would.

Neil2

[insyncro]

If the vinyl in not loose at the areas where you need to cut, I would flush cut around the hole.
That is how the stock vinyl panels are done on my 91 base model.
I checked today.

If you need a picture or two of the basic stock panel's finish I will gladly post one tomorrow while at my shop.

[randywebb]

I think I'll cut it flush. Thx for the offer but I retained a stock panel - it might help others tho.

BTW - their prices are outrageous for what you get. We need some competition for interior panels.
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1986 2.1L Westy 2wd Auto Trans.

[insyncro]

I use fresh tempered masonite, cut from pristine panels I have saved from vans over the years.
I run all edges on the router, than cover them or laminate exotic veneers to that.
The sky is the limit is you have the time, some tools and skills.

Werksberg makes nice ABS panels:

http://www.thesamba.com/vw/classifieds/detail.php?id=1007450

[randywebb]

modern cars use a type of foam board, skinned or bonded to something on both sides

it is lighter than masonite (or luan) and impervious to water - a co. called appbiz makes panels for Porsches (old 911s) that way

Sewfine knew nothing about that when I asked them

I did cut the holes flush and also located some holes for the map pockets - much more laborious than I wanted ...
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1986 2.1L Westy 2wd Auto Trans.

[insyncro]

Yes, I am familiar with those panels.

I have found some really cool sheet materials while building sound rooms for a few Jazz musicians who are building clients of mine.

I haven't tested any of them in automobile applications yet, but once I do and they are even somewhat successful, I will post info about them.

Glad it worked out well for you.

[randywebb]

Thanks.

I know you have your hands full (or your web site or HDD full), but someone ought to fab up panels of the Vanagon using the foam board...
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1986 2.1L Westy 2wd Auto Trans.

[insyncro]

MDF can also be used.
Many of the custom audio and interior builds on various TV car shows gloss over how easy it is to work with and just show it being ripped on a table saw.
Layered, built, routed...it takes puddies really well, isn't that heavy and is super cost effective.
Foam and especially foam products that do not hold or attract moisture are on the expensive side for most.

Interior panels....I'll add it to the list.
Thanks for the vote of confidence

[Steelhead]

Randy - I would cut and "X", fold through, trim a bit, and glue.

All - I'm tellin ya, covering a werksberg ABS panel in 1/8 neoprene makes for an excellent starting point. The neoprene has a great feel (under tweed in my case), it hides the clips (original hidden style, not the exterior screw-types), and it adds some awesome sound dampening. I'm hoping to complete the rest of the doors this weekend. I'm sure sewfine's are well made but I really wanted these door cards to be impervious to moisture and I was particularly interested to see if I could sew up my own design. Not sure the end product will be any cheaper than a custom Sewfine job, but being non-masonite these should last forever and can be recovered down the road (tweed fabric is glued only to back of ABS board, not to the neoprene).

here's the neoprene going onto the ABS panel.

missing door handle...

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'77 Bay Window / '89 Caratsburg (aka. the Stormtrooper)

[insyncro]

Steelhead,
I laminated EPDM rubber for an industrial look, to panels of a contractor's work Vanagon years ago.
Worked great.
Nice job on your panels!