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Old 05-05-2021, 01:05 PM   #1
OldCarNewTricks
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Default Repair my Door Panels?

Hello, as I am sure so many people are aware, the door panels (or cards) in the 240s are not entirely water proof, so, as such, my poor door panels are shot on my 242. I got some door panels with the vinyl in really great shape from a member on TB. However, the masonite hard board is also in really bad shape on these, as well.

I was wondering what you all have done to repair these? My initial thought was fiberglass resin, but getting the panel perfectly flat before and during the process would be a challenge, I expect. I was also thinking of carefully peeling the vinyl from the panel and replacing the panel?
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Old 05-05-2021, 01:08 PM   #2
lookforjoe
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Use the old back board as a template, and cut new ones from fresh board. I'd be looking at Home Depot, etc., for a suitable replacement backing material.
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Old 05-05-2021, 01:36 PM   #3
OldCarNewTricks
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Originally Posted by lookforjoe View Post
Use the old back board as a template, and cut new ones from fresh board. I'd be looking at Home Depot, etc., for a suitable replacement backing material.
My only concern is that the factory panels are molded into their shape. I'm wondering if they would look all that different if they were flat?
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Old 05-05-2021, 02:26 PM   #4
Khrrck
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Originally Posted by OldCarNewTricks View Post
My only concern is that the factory panels are molded into their shape. I'm wondering if they would look all that different if they were flat?
If you look at the back of the board, the molded section doesn't provide clearance for anything in the door IIRC.

So, you should be able to use a flat board, and then pad out with a dense foam (recommend upholstery foam for longer life) to match the previous shape on the fabric side.
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