Any magic tricks for lining up existing panel screw holes?

[staceyz]

If possible I'd like to use the existing panel screw holes I have in my 58 dlx to put new panels on. Has anyone thought of a clever idea on how to make new holes in new panels to match the holes? (I hate the idea of drilling more holes..) Love to hear any creative suggestions... Thanks, Stacey
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Wanted: Old Martin or Gibson Guitars

[steve mighetto]

Make sure the new panel fits.
Trace the new panel onto paper and cut the paper to match the panel.
Move the paper to the panel location and mark the existing holes.
Move the paper back to the new panel and transfer the hole locations to the new panel.
Paper you can see through works best.
Measure twice cut ounce rules apply.

[Clara]

some panels use pre-drilled holes, such as rear hatch & cargo doors

others don't
kick panels, long side panel, corner panels
Who ever installed them just drilled. There
was a standard number of screw used, but not exact spacing.
I've used the pencil mark and push a safety pin through it trick. You have to get really accurate. But if you use a pin, teh errors are
yon't as noticable
You also want to make sure your old holes aren't over sized before drilling the new panel to he old holes.

You can use a hammer to tap the holes flat, which makes them smaller.
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[grumpyveedub]

[hugheseum]

the slip over trim clips that are sold with speakers or other automotive brands work,use a smaller screw that that of the stock vw screw,go thru all the holes opposite so the pointed end is facing out,get the panel up to it and tap the panel with a rubber mallet on the edges,pull it off and it should be marked,theres more than one way to skin a cat,just depends how bad you want it
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Have a great day!

[VWsArent4Hippies]

http://www.yardstore.com/browse.cfm/4,4125.html
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[NorCalWeekender]

I've used an awl to find the hole and then hold the panel there while I set the screw.
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[langsmer]

Try using a thin wood slat that is the exact same length of the panel. Drill out the holes in the correct positions on the slat, mount the slat up to make sure the holes are in the correct position, then use the slat as a guide on the panel where to drill the holes. I hope that makes sense!

[Major Woody]

I used a full sized heavy paper template. At Home Depot, you can buy some very heavyweight paper used between hardwood flooring and the subfloor. This works excellent. Make a mark on a piece of blue painters tape adjacent to the hole where the template paper will NOT cover it. This will help you find the hole with your awl. Fit the paper into position, tape it in place, poke all your holes, double check the fit, and then transfer the holes onto your panels. Again, the blue tape will help you locate the holes in the bus when you go to drive your screws.

Make the holes in the panel oversize so the panel will have some room to move with humidity. This will help prevent warpage.

[staceyz]

Cool, thanks everyone, I'll use the template method...! Stacey
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Wanted: Old Martin or Gibson Guitars

[cru62]

Before you make a template, consider using just masking tape. Put a piece at each hole, continuing outside the limits of the panel. Use a straight edge to mark a "+" 3/4" to 1" away from the hole. Put the panel on, measure the required distance from the "+" and mark the hole. Easy, peasy!
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[57palm]

You just need to use a hole finder. it is used extensively in aircraft sheet metal and other applications and easy to make yourself. Here is how it goes to make your own.

take two hacksaw blades lay them on top of each other and screw one end together through the holes. The holes in the other end should line up perfectly. Now in one blade hole on the other end fix a small screw or rivet that will fit in the door screw holes. do not make it long or you will not get it in under the panel. Now fix you door panel to the door with a few screws. use the hole finder for the rest by sliding the one blade behind the panel and get the rivet in the hole. Line the other blade up with the one in the hole. The hole in the outside blade will perfectly locate the screw hole for you. Do this for all holes and voila!! no mistakes.

Or you can just buy one from an aircraft tool vendor.


Reuben

[dstefun]

[VWsArent4Hippies]

[dstefun]

[Olymale]

I always see that making the hole with a drill is the preferred method here. How many people have tore or spun and stretched the new panel material while using a drill? I secured all my panels in my 65 with stainless screws but used a leather punch for doing the holes. Works perfectly and the leather punch tool has 6 differant hole sizes to choose from. I also use the aircraft style hole finder.
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[staceyz]

Awesome... what a great tool! Also love the leather punch idea too.. Now I'll haver made in the shade with Kool-Aid..
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[mynameismud]

careful your screws don't strip out. this happened when i used the existing holes for the door panel cards..now i get to redo the panels and move the holes over to get fresh metal.
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[powellscooter]

I used the clear plastic sheet method, as I had a bunch of holes I didnt want to re use. I cut the template from the new panel and positioned it on the door, marked where the holes were, then put the template on the new panel and drilled thru the template and panel into the door where I knew there would be fresh metal. ONE WORD OF ADVICE.... start on the top outer corner and work across toward the vent window first, that way you will not have a gap where the door bends just below the vent window. Ask me how I know this.......

[mynameismud]