Replacing/redoing interior panels/door cards?

[JFW]

Hi guys!

Quick follow up on this thread: Are there any DWG/DXF files for the door cards and interior panels available out there? I've been dooing my best google-fu to no avail. Considering just making some myself (files + cards/panels).

Truls

[SyncroHead]

[joetiger]

Great to hear! The Vanagon List Archive is still a great source for info.
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Joe T.

'86 NAHT Vanagon GL Syncro/ supercharged ABA 2.0 "Pigpen"
'04 GTI 1.8T
'04 Golf R32

"get metaphysical with it. if it's simply a means to get to and from places, it will let you down. if it becomes your zen, it can't fail you." -dabaron

"Still, it's good to be afield."--VWagabond

Available Now! Vanagon to Louisiana--A Two-Lane Reckoning Through Past and Present

www.josephtrussell.com

[Joe Cole]

Did anyone ever come up with dwg/dxf or Ai files for any of the panel/door cards?

I only know 5 people with a cnc machine and I own a shaper origin. I guess I can flatten my least warped door panel and copy it but a clean AI file would be amazing.

[ZsZ]

[JFW]

In regards to CAD files for the panels. The topic is covered here now: https://www.thesamba.com/vw/forum/viewtopic.php?t=738392

Truls
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1986 Caravelle C Reimo camper (AAZ TD)
1989 Caravelle C Syncro (JX TD, 2xdifflocks, PS)
Museum director.
Bicycle framebuilder.
Thinkerer.

[jcannon]

For those who want to make new hardboard (masonite) for their existing door panels there is a way to make your own pattern if the existing one is too ratty to be usable.

Tape some kraft paper (it comes in rolls) to the door panel indent and cut it so it fills the indent to the edges plus a bit. Use a compass or divider set to 1mm or so and trace the inside of the opening. You now have the outside line of your pattern. Rub your thumb on the clip holes and it will imprint the paper with the exact locations. Do the same for the door handle screws. Cut out your new panels. There should be enough left of the old panels to trace out the openings for the speakers, door latch, window winder or electric switch, and mirror control. As they say, "All too easy".

Next, I have two ways to get the vinyl off the old card. The first is to use a sharp wood chisel, bevel down, and slice (pare) the masonite off beneath the heat seams. You cut just deep enough into the masonite so the vinyl does not get cut. This will leave a small amount of masonite stuck to the vinyl. Sharp means sharp. Your chisel should be able to cut a sheet of paper. Paring the masonite is a one hand affair and it goes quick, if your chisel is sharp. The chrome strip is plastic so no problem there. The seam under the carpeted portion is much wider than the heat seams but will pare of easily. To remove the masonite from the vinyl, toss it in a tub of water. This works really good for a panel you want to trace that is too bad to use but you still want.

If the panel is so ratty it is unusable, like one of mine, soak it in the tub until the masonite falls apart. That is my preferred way. Little labor involved. Make sure you do this after you've traced the openings.

Panel clip holes are 10mm. The chisel was probably 1". If not 3/4. If you can't sharpen a chisel it is a useful skill to develop. Google Paul Sellers. If you are thinking you can buy a new one and they come sharp, good luck. Even the expensive chisels require user sharpening.

If you are doing many Vanagons the dxf and a cnc is preferable. I'm an engineer and it would take me some time to be sure a dxf file was perfect. The pattern takes me 20 minutes and the cards come out perfect. For me it is the fastest way to make one set.

For things like the speakers which work best with nice exact holes, cut them a wee bit small and ftf. (ftf = file to fit)

I'm more of a convertible person and have had several of the early '50s Karmans. To buy panels is very expensive. They are almost unfindable for tracing, so the paper was my process. For those you need to offset the clip holes.

This works for flat glass too, if you need a pattern. Paper in the opening, run a compass/divider around the edge and poof! Measure the gasket to get the offset.

[1971BugGuy]

Made my own door cards out of Masonite and sewed my own covers. Installed new Kicker speakers in the stock speaker grills, added new door pulls and window cranks. FYI, Ford Taurus window cranks offer more than twice the clearance over the speaker as the VW ones. Unfortunately I was unable to locate new door release escutcheons so I had to reuse my fatigued old ones.

[/img]
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Only a fool or a child would judge a project before it reaches its completion.


1971 Super Beetle
1986 Vanagon Westfalia Weekender

[DuncanS]

Very nice.

[jlrftype7]

[IdahoDoug]

Wow, that interior looks amazing. That was a serious labor of love and you are a well balanced detail freak. I even like that you turned on your map light for the one picture. That is one loved Vanagon and she's in the right hands. A tip of the hat across the miles...
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[Alaskaberrys]

Wow, beautiful interior details! Nicely done.
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'91 Westfalia, Bordeaux Red Pearl 2.1L 2wd Auto
'91 T3 Syncro Doka, Escorial Green 1.9L TD AAZ “Gremian” (to provoke, irritate, exasperate, vex...)

[1971BugGuy]