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Old 06-21-2018, 04:22 PM   #1
Uncleknucklez
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Default 242 Fabricated door cards

I threw these pictures up on IG, but I figured there were individuals who would be interested in seeing this that aren't on there. So....

I decided to design a file to rout out some 242 front door cards from aluminum earlier in the week. Volvo did us 240 guys a tremendous solid by making the doors essentially flat, with only a few minor bumps.

This is a pic of the original file I drew from a tracing of a spare door card I have



Here is the card after routing



And installed







Plan is to add material at the top, that will get break formed into a "radius" and have a flat to attach the inside window scraper. This card can re-use all of the OEM door parts, and I will run a strip of felt tape on the high parts of the door so there should be minimal rattles.
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Old 06-21-2018, 04:41 PM   #2
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I'm curious to see the end result after you finish it off. My wrinkly door cards have been bothering me for years.
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Old 06-21-2018, 05:02 PM   #3
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What are you doing for the upper panel curve
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Old 06-21-2018, 05:12 PM   #4
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Ahem...

http://m.mkmotorsport.se/products/vo...dor-brandvagg/

Do it like that.
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Old 06-21-2018, 05:43 PM   #5
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What are you doing for the upper panel curve
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Folks on here don't know a good deal when they see it.
how psi stock cna support?

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Old 06-22-2018, 03:45 PM   #6
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Update:

I broke the top with multiple flat bends, seems like it will work fine.





This area needs file work


This area seems "OK"


Because racecar I slapped some stripes on the prototype.




I will continue to adjust the file another time, and hopefully have a finished product by the middle of next week.
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Old 06-22-2018, 03:59 PM   #7
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Adidas?
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Old 06-22-2018, 04:02 PM   #8
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Adidas?
Meh, why not. It's just sign grade vinyl, So it can be peeled off. I also have a large format digital printer in my shop, and could pretty much print anything and apply it. This was something that took 5 minutes to cut and apply.
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Old 06-22-2018, 04:03 PM   #9
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Russian ?
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Old 06-22-2018, 04:06 PM   #10
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Russian ?
That squat tho...
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Old 06-22-2018, 04:10 PM   #11
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That squat tho...
Slav squat YouTube dude is hilarious
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Old 06-22-2018, 04:38 PM   #12
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Russian ?
Romanian taxi car driver.
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Old 06-22-2018, 06:27 PM   #13
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Are you going to produce a couple of these?
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Old 06-26-2018, 10:00 AM   #14
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Are you going to produce a couple of these?
I plan to make my final set today, and if everything goes well, I can produce reproductions no problem, I realize this isn't the classified section, but for reference I am thinking $160 shipped for the set will put them within reach of the TB crowd, and still make sense for me to produce them.

That being said aluminum prices right now are rough

Last edited by Uncleknucklez; 06-26-2018 at 11:25 AM..
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Old 06-26-2018, 10:56 AM   #15
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I'd put some squares of butyl based sound deadening material (rec. RAAMmat). Might also be a good idea to use some strategically placed butyl rope strings squeezed down around your mounting perimeter. I can see that big piece of aluminum being a rattle and drum factory otherwise.
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Old 06-26-2018, 11:25 AM   #16
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Originally Posted by Stiggy Pop View Post
I'd put some squares of butyl based sound deadening material (rec. RAAMmat). Might also be a good idea to use some strategically placed butyl rope strings squeezed down around your mounting perimeter. I can see that big piece of aluminum being a rattle and drum factory otherwise.
My doors are covered in Noico sound deadening material.
I lined the high spots of the door frame with felt tape, and ordered some edge trim to combat that. However I am finding that these are quieter than the squeaking sounds the factory blown out door cards make as they rub the sill guard.

The real rattling right now is at the window where the scraper should be that I haven't installed yet.
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Old 06-26-2018, 03:46 PM   #17
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Originally Posted by Uncleknucklez View Post
the squeaking sounds the factory blown out door cards make as they rub the sill guard.
my eye is twitching... it's the WORST. Problem on my car as well.
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Old 06-29-2018, 12:10 PM   #18
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Honestly I like the pink!
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Old 06-30-2018, 12:32 AM   #19
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Honestly I like the pink!
Simple statistics would predict that ...
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