Building door panels

[SinWolf]

Ok guys... These pics are step-by-step, and I don't think any explination is required... But if you do have any questions, feel free to ask :)


http://i54.photobucket.com/albums/g91/SinWolf2001/DIY_Doorpanels/DIYDSC00127.jpg


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[SinWolf]

http://i54.photobucket.com/albums/g91/SinWolf2001/DIY_Doorpanels/DIYDSC00487.jpg


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[bentleyrb]

Those door panels are beautiful.
Thanks for the write-up.

[kimokalihi]

wow. How long have you been making these? My next step is to try my hand at some vinyl work.

[cheesehead]

Thanks for the pictures!

What is the white material you used around the speaker rings and crossover holders to round out the corners?

[02bluesuperroo]

Thanks for the pictures!

What is the white material you used around the speaker rings and crossover holders to round out the corners?

Body filler?

How long did this process take? They look great.

[SinWolf]

Body filler?

How long did this process take? They look great.

100%

The white stuff is body filler... These panels took me quite long to build, probably about 6 weeks or so, but it's because I only worked at in the evenings after work...

You can make these much quicker if you work the whole day on them !!

Thanks for the compliments guys :)

[Entityofme1]

They look great. Very clean and simple. I hope that the integrity of the body filler will hold in the long run. For that extensive amount of filling I would have opted to use duraglas which is fiberglass reinforced. It doesn't spread as easily but it still can be shaped well enough and sanded for the same application while adding superior strength and resistance to sinking over time with weather changes.Here where I live our seasons go from very cold to extremely hot and humid. If I were to have used a basic body filler for a project like that I'm sure that over the course of a year or two it would start to pit or sink. I'm not by any means bashing the end result. I'm just hopefully providing some advice that will allow for your next build project to be stronger so it will last longer.:)

[AzGrower]

WOW. cool!

[bdubs767]

how did you attach that piece to the actual door?

[bikinpunk]

how did you attach that piece to the actual door?

Exactly what I was going to ask.

[Genxx]

Great job those look awsome. I hope my stuff turns out that good. I really like your design and how you incorporated everything. Thanks for the step by step pics.

[fastev]

What kind of glue did you use on the vinyl? I've never been able to get it stretched that tight without lifting. Thanks!

[BassBaller5]

ive always used 3m super 77. really messy stuff but never had lifting. i also think hes using that scerw driver to stuff it into the cracks between the two pieces.

[the other hated guy]

ive always used 3m super 77. really messy stuff but never had lifting. i also think hes using that scerw driver to stuff it into the cracks between the two pieces.

super 77 will never hold up to heat...and after awhile it will lift...any of the
3m stuff lifts...

[jearhart]

super 77 will never hold up to heat...and after awhile it will lift...any of the
3m stuff lifts...

then what would you recamend?

[the other hated guy]

then what would you recamend?

if your only option is spray can...then the stuff that Rick over at Raamat is awesome

http://www.raamaudio.com/cgi-bin/index.cgi?p=pr

[Thumper26]

what else besides a spray can?

and how did you attach those to the door panel?

[the other hated guy]

what else besides a spray can?

and how did you attach those to the door panel?

use a pot sprayer and professional glue...that's the best way

[the other hated guy]

what else besides a spray can?

and how did you attach those to the door panel?

and all he would have had to do to attach the pod to the panel is either use thread inserts or tnuts on the back of the pod and screw from the back side of the door panel to attach...

[SinWolf]

how did you attach that piece to the actual door?

Hi,

The panel was fitted to the door card with screws (from behind the door card into my panel)... But this is not enough, because of the weight of the new pannel. So what I did is: Before I mounted the speaker, I installed a nut and bolt through the panel to bolt the panel to the door itself....

http://i54.photobucket.com/albums/g91/SinWolf2001/DIY_Doorpanels/DSC02572.jpg


And the crossover was also bolted through the panel, directly onto these extra bracing strips I installed...

http://i54.photobucket.com/albums/g91/SinWolf2001/DIY_Doorpanels/DSC02595.jpg

So the door card is not only fastened using the OEM clips, but also the extra bolt, and the 2 bolts at the crosover. This is more than enough support for the panel and door card :)

[SinWolf]

What kind of glue did you use on the vinyl? I've never been able to get it stretched that tight without lifting. Thanks!

Well, here in SA we have experimented with alot of glue, and find the PEKAY contact adhesive to be the best...

http://www.pekaygroup.com/fu.html

I'm not to sure as to witch formula we used, but I think it was the V446.

[vwtoby]

exellent wrapping china ;)

whats next for the citi?

cheers

[SinWolf]

Thanks all for your compliments....


exellent wrapping china ;)

whats next for the citi?

cheers



Well.... I need to fabricate a trim panel in the boot to house a LCD screen, and to neaten up the boot area... And then, I need to fabricate a centre console which shall also be used to house my PS2 ;)

[scott_fx]

your work is top notch and inspirational to say the least

[W8 a minute]

In 6 weeks you did more in your backyard, using a tree stump than I did all summer with a fully equipped wood shop/garage.

I feel like a loser. :(

[SinWolf]

In 6 weeks you did more in your backyard, using a tree stump than I did all summer with a fully equipped wood shop/garage.

I feel like a loser. :(

I used that tree stump as a base for my "custom" router table :blush: :blush: :blush:

[a$$hole]

Very nice, Sinwolf !!

1] skill = 10
2] imagination = 10
3] treestump = priceless :D

[Turborusty]

I'm forced to pay someone to build them for me.......as I own neither a tree stump nor bricks:(



Turborusty

[thazy2]

wow! make me a set : )

[60ndown]

ive removed about 15 door panels in the last 20 years, never once got 1 back on right. i break the plastic clips. and often tear the board in my 'passion' :blush:

[lotusing]

You did this after work? What type of work do you do and if it not installing than you are in the wrong line of work.I know places that would pay big for your talent:)

[SinWolf]

You did this after work? What type of work do you do and if it not installing than you are in the wrong line of work.I know places that would pay big for your talent:)

:) No, I'm not in the sound industry ;)

I finished my studies as an Electronic/Computer Engineer about 2 yrs ago, and is busy with my 3 yrs Engineer in training, so that I can register proffesional...

Car audio is a side-line hobby ;)

[GlasSman]

Top notch work.

What vinyl did you use and was it easy to work with?

[rapsucks_07]

whats the white stuff u used to make the curves. looks like really smoth bondo. also looks easy to work with

[Steak]

whats the white stuff u used to make the curves. looks like really smoth bondo. also looks easy to work with

that's body filler...

[bobditts]

The white stuff is body filler...

whats the white stuff u used to make the curves.

;)

[GlasSman]

Nice.

[Horton Hears The Who]

My applause also! Just beautiful. I would like to see the end result. Pictures of the doors finished and I'm surprised nobody asked to see a picture at night with those custom door lights.

I was also interested in how the wiring made it from the crossover to the speaker. I'm guessing there was a little trough routered out.

The only downside I see, and it's not his fault, is the speaker terminals. I've had this complaint for years. Spade connectors have no place on high quality speakers. You go to all the trouble of installing good quality wire and it ends up making poor contact on a spade connector.

After a few months of vibration and temperature cycling what do you think the resistance of that connector is?

[oneiztoomany]

amazing work, more finished pics please!!!

[beastmode]

you did a really good job i like all of the pictures.

[SinWolf]

Thanks guys !!!

I have removed the door panel "inserts" because I want to re-cover them in another shade of gray vinyl. I'll be finished in a month or so, and then I post some pics ;)

[Rockin'Z28]

I love the effect of the letters under the vinyl. Where did you get them?? How thick are they??

I'm trying to get that same effect by using a CNC to carve a logo into the top of my Sub box. My letters are 1/4" high, but the MDF keeps separating and I'm left with only half a letter, or a stub of a letter.

Thanks.

[SinWolf]

I love the effect of the letters under the vinyl. Where did you get them?? How thick are they??

I'm trying to get that same effect by using a CNC to carve a logo into the top of my Sub box. My letters are 1/4" high, but the MDF keeps separating and I'm left with only half a letter, or a stub of a letter.

Thanks.

Ok, I'll spare you ALOT of time and explain how I did it ;)

What I did is, I glued a piece of of-cutt vinyl where I want the lettering. Then I used a hertz sticker and I stuck it on the vinyl (you can also print the writing on a pc)... This sticker was my template...

I then cut the along the lines of the sticker, and removed the vinyl that will NOT form part of the logo... like this...

http://i54.photobucket.com/albums/g91/SinWolf2001/DIY_Doorpanels/DIYDSC00565.jpg

On the pic, you can clearly see that the "logo" is a vinyl logo...

Then you just cover over the vinyl logo. Make sure you get the glue niceley inside the corners of the logo...

http://i54.photobucket.com/albums/g91/SinWolf2001/DIY_Doorpanels/DIYDSC00568.jpg


^^^^ Like this.....

And then you cover it, and take some extra time to press the covering vinyl nicely inside the corners of your logo, to make it stand out more !!!

[Rockin'Z28]

That's a beautiful thing. Thanks for the reply. I was sitting at my computer right now plotting out the logo I want. I was going to cut out the letters individually and try to align them. Your method will save me a lot of hours and aggravation.

Thanks a ton!!! :D

[NeverEnuffBass]

Amazing job, I love doing raised vinyl projects.

[CHH777]

Those are simply beautiful. Excelent work.

[yermolovd]

Your work is the inspiration for my project that I'm starting tomorrow.

I won't be attaching a speaker to the panel, I just need to modify my panel to house an 8" grill and the driver will go in the door.
I have a question about body filler, will it hold together between plastic panel and mdf ring? (I'm blending them together).

[GeoffB]

Nice builds, and a great tutorial.:)
I just noticed its a south african citi (mk1) golf too. Reading the thread the doors looked formilier to me for some reason but it took me a while to twig why lol. There not quite the same layout as early mk1's like mine but at least they moved the window winding mechanism and winder handle on the newer cars.
Very nice and its very rare to see systems in mk1s i must find and visit some SA forums to try and see some more examples.

[EMU]

very inspiring work you've done! wish i had half the skills!

[AzGrower]

het mooi werk tot dusver heren!

tot ziens

[something2003]

why did you use two different colors of vinyl

[BassBaller5]

why did you use two different colors of vinyl

probably because it offsets each other perfectly! :D

[jj_diamond]

sickness.




very nice work! :o

[dsg74]

Great looking door panels! Very similar to what I was thinking of doing in my truck. Try http://brandsoftheworld.com/categories/ to find logos to print out.

[dsg74]

Great looking door panels! Very similar to what I was thinking of doing in my truck. For anyone who is interested, try brandsoftheworld.com for logos you can print out.

[dsg74]

Nice door panels! Very similar to what I'm wanting to do in my truck.

[BlackSapphire]

Great looking door panels! Very similar to what I was thinking of doing in my truck. Try http://brandsoftheworld.com/categories/ to find logos to print out.

Nice find!

[hemi4me?]

Man those are perfect in my eyes I love them

[sirsleepsalot]

Very impressive... might have to steal a couple ideas... :P

[daGwagon]

BUMP for finished product pics? night pics
VERY nice looking panels... i wish i had flat door cards :(

-Garrett

[SinWolf]

BUMP for finished product pics? night pics
VERY nice looking panels... i wish i had flat door cards :(

-Garrett

Hi,

Sorry, but the car has been stolen about 4 months ago....

[blackwolf]

Hi,

Sorry, but the car has been stolen about 4 months ago....

Sorry for your loss. I know first hand about the anger and frustration that goes with having a vehicle stolen.

For what it's worth, thanks for the great tutorial and good luck to you.

[daGwagon]

Hi,

Sorry, but the car has been stolen about 4 months ago....

:o:o:o:o:o:o:o
damn dude that sux sorry bout that
thanx for the write up tho very nice looking panels:)

[lyttleviet]

wow... I am a big Hertz user and that work looks amazing............. DROOOOOOOL >.<