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Old 01-28-2005, 09:43 PM
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Door Panels

Guy's I have a question about door panels. I plan on using 1/8 inch hard board (don't know what it's called but it is the hard dark brown stuff you get at the hardware store). Now the question is, how do you prevent the bolts on the door from causing it to stick up.

This is hard to explain but if you go to my project journal there is a picture of the door. In it you will see all of the bolts are recessed so a flat panel will cover them, except the four that hold the door latch on.

I'm thinking I may have to use two panels. One with cut-outs for the bolts and clips fastened around the edge, and then glue one over that, to make a clean flat surface. However if I do this, the panel will 1/4 inch thick and may not fit under the window trim.

Any suggestions. Rick

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Old 01-28-2005, 10:18 PM
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Old 01-28-2005, 10:30 PM
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We used to call it Masonite, now its tempered hardboard. What are you going to cover the panel with? If it has any thickness to it. I would make the cutouts for bolt clearance thru the panel. Then, if the bolts don't actually come thru the cutouts. I would cover the panel with something light just to keep the bolt heads from touching the backside of your material backing. I have used the aluminum tape that is used for body repair. It is undetectable after the panel is covered. I have also used it to hold in the trim attachment clips along the edges and bottom of panel. It keeps the clips in place and doesn't show thru. I usually use the old VW beetle wire style clips with a small hole in the door for them to expand into.

By the way. GREAT JOB SO FAR!!!!!! I used to pass an old Caddy like that every week back in the seventies. It was setting alongside Michigan 115 north of Clare at an old abandoned gas station/restaurant. Never could find anybody around. Then it vanished.. Hope it met as good a fate as yours has..
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Old 01-30-2005, 05:35 PM
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Temporarily screw the panel onto the door. Everywhere there is a bolt or screw head that sticks out, push in on the panel. This should leave a smal indentation. Drill holes through each of these indentations. Your panel should now fit flush on the door.

But you were right on with your assumption, but the first thicker panel gives you our structure, you dont need a thicker second layer. Use a real thin pressboard, or even a piece of chipboard. Your really just need something that will cover the holes and wont allow the material to "sink" into the holes.
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Old 02-08-2005, 08:57 AM
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Thanks Krist, makes sense.
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