The Upholstery Forum

Restoring / preserving my 39 Packard and just completed an engine rebuild, now onto the interior. Around 3AM, I realized that the techniques in these classes may not be correct for this vintage of car. The door panels are not original and are of a thin cardboard covered with broadcloth, hence quite thin. I like the idea of Luan ply, closed cell foam and then the cloth, but how thick is too thick or put it the proper way, how thick should these panels be?

Thanks in advance

john

@jwblazek Have you searched the internet for other Packards to get a "feel" for what is correct?

I would personally disagree with your thoughts that John's procedures are incorrect for your car and then in the next sentence suggest you are going to use Luan which is also incorrect. If you want it to be correct, you will have to go back with the cardboard door board and nobody will think that is a good idea. Regardless of what you use, it will be out of sight so why not use the best material you can find for the job?

John Long

The technique I was referring to was the layering / accents he embeds in the door panels. I want to do that, but the overall thickness will be a problem I believe
I drive this car quite often and am more concerned on how it looks rather than if it is original in construction. I have been unable to find ABS locally and shipping costs will certainly be outrageous hence opting for Luan ply. So, 1/8" Luan (or ABS, same thickness) plus a layer of closed cell 1/4" foam plus the broad cloth adds up to over 7/16" and the panel I just pulled off is closer to 3/16, using cardboard, a thin layer of cotton batting and the broadcloth. If I opt to use 1/8" closed cell foam, I can't figure out how to do an accent strip in the door the way John shows

Another option and one I use is PVC solid core panel. It is less than 30 bucks for a 4 x8 sheet and will hold glue and staples. Also, it is waterproof. The Luan will certainly work. It just isn't my favorite.

Reviewing John's video on door and deck panel, recalling his valid statement about the rear deck lid, under the window, getting exposed to heat and warping
In as much as this car sees most of its sitting time in the hot California sun during tours, car shows and the like, concerned about using anything but Luan (cardboard or something simiular is not an option, I don't like it) for fear of the warping factor.
Comments are welcome!. Receiving fabric samples this week, have closed cell foam in 2 thicknesses arriving today alon with two thicknesses of jute for the carpeting. Finished my first door template yesterday, getting antsy to start !

luan is great..................... , I cant believe the 39 packard had that much definition in the panels that it wouold be that thick. there are other ways to do it with different materials to thin it out

Hi @jwblazek Welcome to the forum!

The way I showed how to do custom door panels in the videos is the most popular way to make door panels with a more modern look. The thickness will work and look fins as long as you amke sure to fit and clearance everything correctly. For example how I trimmed the foam to the shape of the top trim piece so that it still sat correctly when installed.

That being said if you are going for factor look there is no reason you cant do that as well exactly the same way they were don previously. Making older panels like that are usually fairly simple to do.

As far as the warping goes... I ran in to that problem in the phoenix summer sun where its 110 outside and 140 inside a car with closed windows. You would probably be ok using ABS but luan is a great option as well. PVC board apparently works fantastic as well.

Hope this helps!