Im new here, and I have learned that not doing searches will get you flamed, therefore I did a search and read through 6 posts on making a door panel and was hoping to still get some help.
I have an 1987 chevy full size c10 and want to make my own door panel. The problem is, the door is not flat and im estimating an 1/2" border will be to be attached to the masonite throughout all the edges to give it the up to become flat.
I already bought a sheet of 2x4 masonite and it will be sufficient for one door.
I read about using cardboard for the first design and since I tried workin with posterboard once and it was too flimsy and just kept falling around while trying to work on it myself, I will be using the cardboard method to get my design.
Here is the problem im having... as I said I bought the masonite and I already have all the fiberglass materials needed for one of two actual problems/questions I have..
(1) Im using fiberglass because the door panels in my truck have a curved shape that forms the top part of the panel where the door lock is so I am having to take that mold off just the top part of the panel in order to make it flush... that I think i can do and then just attach it to the masonite.
Problem (2)... Do I HAVE to use some type of foam on the door panel before wrapping my tweed material? Im taking a shaped type of door panel and transforming it to a flat type of door panel for a hot-rod style look. I understand addin the foam would make it softer but with it already going to have a flat 1/2" raising edge, how thin of a foam can I add and buy locally to put on my masonite?
I understand the problem with the possibility of Masonite warping over time but (1) it will not be wet and (2) once these panels are made they will be sitting inside in a closet for 3 or 4 months until I have the rest of the cab inside and out primered for paint and put it back in for simply test fitting. Then once the truck is under complete primer and i put the interior back in for show season next year it will be car covered... therefore heat should not be an extreme issue with this truck and it is Not a daily driver.
Attached is a picture of a stock door pane my style truck and the panel im creating for the hot-rod look I want.