How do I install door panels?

[West Texas Z]

I bought a pair of aluminum door panels for my interior and I was curious how would I go with installing them? I want a clean look like with rivets but I would be screwed if I ever need to pull them off to repair a window or something. Any ideas experts? :dunno:

[Fesler built]

Do a zerc fitting in the door with a nice button head bolt in the panel, they will be clean and can be taken off at anytime...... This will look the best and be easy to do.

[dstryr]

what kind of door panels did you buy?

[70bird]

Got any pics?

[West Texas Z]

no sorry, no pics. I'm going to the storage tommorow and I can take some then.

Whats a zerc fitting? I never heard of that. :)

[70bird]

Whats a zerc fitting? I never heard of that. :)
Maybe so you can lube up your door panels LOL

I think he meant to say Dzuz fasteners: http://www.jegs.com/p/Moroso/748742/10002/-1/11333

[West Texas Z]

ah! gotcha. That would look better that some plain nuts and bolts. Thanks. ^

[osdmike]

Check this out !

http://www.emhart.com/products/pop/popnut.asp

I used "Pop Nuts" when I made this box for the fuelcell tank.
Easy to take apart.(see pics)
I´m sure You can use them for the door panels.

http://www.google.se/search?q=pop+nuts&ndsp=18&um=1&hl=sv&ie=UTF-8&sa=N&tab=iw

[West Texas Z]

Woah osdmike!!! Thats perfect. Are they expensive? I need to buy the tool gun too huh?

[Patrick]

You can get them in kit form by Marson. Most of your local supply shops like Fastenal carry them or can get them.

Make sure you get the rivet nut style...it's knurled and helps to hold it in place.

Here is a link:
http://www.blindrivetsupply.com/detail.aspx?ID=784

[West Texas Z]

thanks for the links. I'll look into that. =)

[Bryce]

any updates and pictures?

[Jim Nilsen]

I am not sure what look you are looking for but here is a pic of my aluminum door panel done with perforated aluminum. I just used black trim screws that I picked up at fastenal, they are the Aweveco brand that they carry. Just a simple screw in black oxide.I used rubber edging that I picked up from Mcmaster-Carr to finish it off.

Hope this helps you. The rivnuts are nice and I have them but decided it was not neccessary and in a few places not quite workable do to the job because of the angles.

[Bryce]

thanks Jim,

Im thinking about .100" aluminum and cutouts in the Al with tweed inserts.

[Jim Nilsen]

thanks Jim,

Im thinking about .100" aluminum and cutouts in the Al with tweed inserts.

If you go with 6061 you could go down to .060 and still be more than stiff enough and cut off some more weight if it is any concern.

Sounds like it will be really nice with the tweed inserts, can't wait to see it done.

[Bryce]

i am going to use .100 so i can round the edges for a more finished look. Weight is a huge concern of mine. The car only weighs 2690 right now.

[Jim Nilsen]

i am going to use .100 so i can round the edges for a more finished look. Weight is a huge concern of mine. The car only weighs 2690 right now.

You can get an aluminum edging that will do the same thing the rubber edging I used does.As long as the radius's of the panel will allow it you can do it without wrinkling it. The inserts you plan on doing may reduce the weight and the extra thickness might be needed to keep it stiff where they are, you could also do both if needed.

I am liking the weight of your car and am curious as to how far you are on the build so far? I was at 2650 and thought I only had another 200 to go and ended up at 3150 so far. I couldn't believe I was that far off in the end. It all adds up so quickly.

Are you going to leave the aluminum natural or paint and what color is the tweed going to be?

Keep us posted.

[Bryce]

Jim check out my build thread.

https://www.pro-touring.com/forum/showthread.php?t=58842

My car is complete with all parts on it. I am currently driving it. More modifications to come.

The theme of my car is satin aluminum, so teh door panels will be satin, they will match my dash and steering column and steering wheel as well as the engine compartment.

[Jim Nilsen]

Jim check out my build thread.

https://www.pro-touring.com/forum/showthread.php?t=58842

My car is complete with all parts on it. I am currently driving it. More modifications to come.

The theme of my car is satin aluminum, so teh door panels will be satin, they will match my dash and steering column and steering wheel as well as the engine compartment.

Nice ,very nice. The engineering concepts are right on track to the way I think I can't believe it.

I remember the days when I was full fledged Ford guy and had many thoughts of lightweight Falcons. You have to make the Blue oval guys more than proud.

Someday somewhere I hope we meet.

[Bryce]

Wow Jim. that means a lot coming from you.

I will be at SEMA this year, If you make it over this way.

[jon72vega]

Nutserts are a good way to get threads where you want them on your door.
http://www.aircraftspruce.com/catalog/hapages/nutserts.php

Then you could use some nice polished SS button-head allen bolts to fasten your trim panel to the door.

[pimtina]

here is a pic of my aluminum door panel done with perforated aluminum.
Where did you get the perfed sheets? I'd like to steal your idea for my Cortina!

[Jim Nilsen]

Where did you get the perfed sheets? I'd like to steal your idea for my Cortina!

Metal Express.

The cost is around $10 per squ. ft., You can pick from a lot of different size holes and spacings and get a lot of different types of the same look. I would have to look at my receipts to get you the exact size I used.

It also only comes in 36" width not 48" so it can make for a lot more waste if you don't plan well. It does however come in 12' lengths which helps.

Glad you like the look ! The more others do it the more it will put a smile on my face. I have never seen it done before and didn't know how well it would be recieved outside of the hardcore racing world.