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[jmdugas]

I just finished the Door & kick panels course. Looking forward to using what I have learned on my TR7.

There is one thing that has not been covered, how to reproduce door cards that wrap around the top of the door (See attached pictures).

Any words of wisdom?

[John]

If the door panel is all one solid piece your going to have to get creative with fiber glass to repair it. Many times the top curved section is a separate piece and is attached to the flat panel. In this case you will be able to reuse the top curved section and replace the bottom flat section.

[jmdugas]

Unfortunately, the panel is one piece.

The original material used looks like very dense cardboard and was probably steam formed with a press to get the top part molded.

I think that the best solution will be to either cut the top part off the original panel (if it is in good enough shape) or learn about fiberglass.

[John]

Yeah thats what I would do too. Fiber glass is pretty easy to use it can just get messy.

[John Long]

I think I might look into making that panel out of 16ga aluminum. The panel appears to be flat other than the roll at the top which could be formed in it.

John

[jmdugas]

I think I might look into making that panel out of 16ga aluminum. The panel appears to be flat other than the roll at the top which could be formed in it.

John

Would the upholstery glue stick to aluminum?

[John Long]

Yes. That would not be a problem.

John

[BigRig]

@jmdugas , This may be better evaluated when the vinyl is tripped off. If you have not done so strip it and post a picture.