I still haven't decided if I am going to use the wood from the old, original armrests or make new. I am leaning toward cutting up the 73 year old armrests and using the original wood as the starting point. Additionally, as if the resin on fleece for the speaker enclosures wasn't enough punishment, I think that is the process I am going to use for the armrest bases.
Some masking tape was attached to the floor and the window box to establish the leading edge of the armrest for future reference.
Masking paper was cut, taped together, taped to the interior panel, and cut to shape. The paper was then removed and attached to the 1/8'' PVC foam board. The leading edge was extended out by the width of the masking tape (1''). The rest of the perimeter was marked with a silver Sharpie.
A variable speed saber saw was used with a 24t metal blade to cut the panel. After some minor trimming, a single Cleco was installed to hold in place.
Made and installed the driver's side tack strip this evening.
Pulled the old headliner off the shelf to verify that it does not extend down the B-pillar. Did a preliminary measure for the cards on the rear seat sides. Pulled one of the foamed PVC sheets out so I can start laying out the cards. Did a preliminary measurement to see how to lay out the cards. Ready to start marking and cutting!
I also looked over one of the stock arm rests, trying to determine if make sense to build new wood pieces or modify the stock wood pieces.
The tack strips have bothered me for a while. The originals disintegrated for the most part. Additionally, the path changed due to the bear claws. I couldn't find tack strip the correct size. I finally decided to use some untempered Masonite. The shapes were cut out and three layers were stacked with contact cement. The Masonite is about the same density as the original strips. The rub is that I may not actually need them! I believe they are for the wind lace which I have decided (for the most part) not to use. Any way, it looks good and went pretty quick. The other side should be even quicker. Then I can get on with the panel cards.
After hours of Bondo, sand, repeat, the package shelf was done. A quick shot of primer revealed all the imperfections. Actually, they are so small, I am the only one who will probably see them. I am keeping my mouth shut.
The left kick panel needs finish sanding and maybe some spot glazing. The right one is on its second, and possibly last, coat of Bondo, so it is close.