Making Aluminum Door Panels

Trim for perfect fit.

Making aluminum door panels.

Building a show quality interior to match the rest of your build can be a daunting task. Although these doors can be easily bought from a home improvement store you can create your own and save some cash by assembling the parts from an aluminum screen door kit. Make three panels each measuring the width of the door by the height obtained in step 2. Step 1 choose a high quality screen door kit product.

Beaded for extra strength. Cut two pieces of 1 by 2 inch wood studs to the width of the door less 2 inches 5 centimeters. These will allow the door to roll freely. This series of videos will walk you through building custom interior door panels.

Features 032 thick aluminum made slightly over sized. Car door panels can be expensive depending on the vehicle make and model. When removing the old panels be sure to remove all staples and hang on to the clips. Test fit your new panel to the door of your car and make sure none of the new panel s edges stick out too far.

To custom make door panels that are strong enough for everyday use and or abuse use fiberglass mat to reinforce the high stress areas like the door pull or armrest for instance cut the fiberglass mat into several small pieces and overlap them when applying to the door panel surface for added strength. Building new panels also gives you the option of using higher quality materials. I had to do this 2 or 3 times before everything fit like it should. Cut an attach the padding and top layers.

However with a little instruction and a broad selection of car interior upholstery parts the task is made easier than you might think. Close the door a few times to make sure everything clears. A kit is the easiest solution when deciding to build your own screen door. Do it yourselfers can build their own panels with a few power tools and glue.

Each of our panels will be 12 feet by 3 feet 3 7 meters by 9 meters. Insert all of the circular pop clips into the new door panel. Rolled to lip for neat appearance. 2 door panels 1 passenger side kick panel in front of wheel tubs 1 driver side kick panel in front of wheel tubs.

Techniques build and assemble door easy how to make a door aluminum correctly. First apply a little resin where the. For most classic car restorers sewing together upholstery is an unlearned skill.