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Old 05-16-2021, 08:43 AM   #1
Jsegura525@aol.com
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Default Rotted away door card bottoms... How to ...

Good morning chaps and chapettes....

I pulled the door cards on a 240 (1982) and there was over an inch of
dirt in the door and the door card lower 1/3 is rotted away. What have you
all used to remove and replace the rotten section?

Thanks in advance,
Joseph Segura
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Old 05-16-2021, 10:04 AM   #2
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Old 05-16-2021, 10:11 AM   #3
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Hard part is getting whatever you use to replace that bottom 1/3 joined with the main card. Then making it lay flat.

I asked a similar question recently: http://forums.turbobricks.com/showthread.php?t=360216
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Old 05-16-2021, 11:02 AM   #4
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Photos please
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Old 05-16-2021, 11:17 AM   #5
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Joseph, is your car a 2 or 4 door? It's much easier to find the 4 door panels at the picknpull as suggested by Redwood.
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Old 05-16-2021, 11:51 AM   #6
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Joseph, is your car a 2 or 4 door? It's much easier to find the 4 door panels at the picknpull as suggested by Redwood.

There hasn't been a 242 in your JYs for 3 or 4 years now.
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Old 05-16-2021, 01:19 PM   #7
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https://forums.tbforums.com/showthread.php?t=346785
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Old 05-16-2021, 01:22 PM   #8
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Sweet! I'd like to do this but reuse the factory vinyl.
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Old 05-16-2021, 03:56 PM   #9
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How perfect does it need to be? You could replace the rotted section with some masonite board cut maybe 3 inches larger to overlap the top edge. Glue it with liquid nails , then attach your bottom upholstery. Take your time , don't forget the cutouts for the clips.
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Old 05-16-2021, 06:26 PM   #10
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How perfect does it need to be? You could replace the rotted section with some masonite board cut maybe 3 inches larger to overlap the top edge. Glue it with liquid nails , then attach your bottom upholstery. Take your time , don't forget the cutouts for the clips.
That's not a bad idea. Could use foam to space the fabric out
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Old 05-16-2021, 09:34 PM   #11
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I've used mesh and resin to do a halfway decent job. The hard part is keeping the skin taut while curing.

I made a jig not unlike a skin stretcher dryer that I learned to do in scouts using binder clips.
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Old 05-18-2021, 12:37 AM   #12
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I've used mesh and resin to do a halfway decent job. The hard part is keeping the skin taut while curing.

I made a jig not unlike a skin stretcher dryer that I learned to do in scouts using binder clips.
I'm intrigued! What did you use as the "backbone" of the stretcher? I was thinking that thin plywood in a similar shape as the damaged area might do okay?
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Old 05-18-2021, 12:25 PM   #13
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I've used mesh and resin to do a halfway decent job. The hard part is keeping the skin taut while curing.

I made a jig not unlike a skin stretcher dryer that I learned to do in scouts using binder clips.
uhr, did you put the lotion on the skin first?
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Old 05-19-2021, 10:44 AM   #14
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Originally Posted by OldCarNewTricks View Post
I'm intrigued! What did you use as the "backbone" of the stretcher? I was thinking that thin plywood in a similar shape as the damaged area might do okay?
It was just 1x1 lumber in a frame about 8" larger all the way around. I also removed everything I could from the card. Once the resin hardened and the card was structural, I manually folded the vinyl back over the edges and glued them in place.

It looked like a murder scene from behind, but from the front, it wasn't bad and even better when it was mounted.

I even managed to re-create the tab holes by trimming plastic soda bottle caps and slipping them under the fabric and trimming them out with a Dremel.

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uhr, did you put the lotion on the skin first?
All the lotion.
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Old 05-20-2021, 08:24 PM   #15
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Hardboard/High-Density Fiberboard (HDFB)/Masonite is very bendable when steamed or spot heated (i.e. with a heat gun). Both methods are used in model making, stage set design, and for things like custom molded pallet caps and inserts.

If it were me, and I was trying to reuse the original vinyl and otherwise keep things as factory-like as possible, I’d cut a new panel backing and make a press jig from plywood and/or aluminum to then work it into shape. Sealing it afterwards would probably be a good idea to stave off future rot.

I’ve been known to go a little overboard with this sort of thing though, so maybe that’s a somewhat excessive solution.
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