You take the cardboard panel and glue it to the curved metal piece with HHR (high heat resistant) contact adhesive. After the cardboard is glued in place, drill some small pilot holes through the cardboard and metal in about five places. Screw the two pieces together with small phillips flat head screws from the back through the metal, and after they are snug, grind off the part of the screw that sticks out flush with the metal.
Attach the new vinyl over the top of the metal with the same HHR contact adhesive. It will not wrinkle because it will already be dry when you mate the vinyl to the metal.
While you're at it, put new belt weatherstripping (window sweep) on the top of the metal. The old sweeps have to come off anyway to glue the vinyl on. You can buy exact replacements on line. Take the staples out that hold them in place. Re-attach the new sweeps with stainless or aluminum pop rivets. I think those sweeps are the kind that fold in half, and only the inside part next to the metal gets attached. You'll need to drill 1/8" holes through the sweep and the metal. Obviously, work from the sweep through the metal with the rivets. No, the bumps on the back from the pop rivets after you're done will not keep the metal piece from going back on the car door.
No one lives forever, the trick is creating something that will.
Last edited by DanTwoLakes; 07-17-2009 at 12:06 PM.