Door Panel Design and Assembly Questions

[Barrrf]

I want to make myself some sweet ass door panels - however - my skills are pretty limited.

So I was kicking around the idea of designing the door panel in 3D and having some of the features machined out of wood? This way I could get some contours on the panel without doing any glasswork on it. I would, obviously, have to figure out something for the curved steel piece on the top that holds the window fuzzy.

I was also considering using wood for the base and then using some sort fo sculpting foam for the contours I want to make? Ive been scratching my head on how those awesome guys at Fesler or RR do it - they have those swoops in the panels that go right through to the back panels. Or how they bump them out and make room for a door pocket.

Any ideas?

[Barrrf]

I see on the Fesler panels they appear to made out of fiberglass. But what is under the fiberglass to give the panels its shape?

[E-Vukets]

I am interested in this as well, I had the same idea with custom wood door panels as a new set of seats I bought brush the stock door panels. I assume from Fesler's price their panels are all made in a mold and vacuume sealed.

[Barrrf]

I saw some tutorials on the web where guys used T-shirts and a staple gun (and resin of course) to get some of the shapes they wanted. But like Feslers panels, how do they make them do damn smooth if they are indeed hand made? Ive got an idea that uses several layers of thin wood to build up the shapes and then use the shirts and resin - but is this the right way?

[E-Vukets]

I found the thread https://www.pro-touring.com/showthread.php?79869-Just-another-Garage-fabbed-Door-Panel-thread&highlight= by protour73 and he seems very knowledgable on materials and such to use. I am planning to use abs like he did or some thin wood as I already have some of that, and then cover it in vinyl. Hopefully some fiberglass pros can help you out, I have not done any research in that area as I need my door panels to be nice and narrow.

[Barrrf]

I dont want to use glass but will if I have to. Most likely for speaker pods. Still considering some billet armrest so I can have a spot to mount a switch for door poppers.

[Barrrf]

Like these panels - how do you guys at the shop get all those contours? Is it really a mold?

https://www.pro-touring.com/attachment.php?attachmentid=44512&stc=1&d=1297725582

[Thephranc]

Look into PVC sheet as building material. Its lighter than wood, more resistant to moisture, can be heat formed and is easier to work with over ABS of acrylics.

[Barrrf]

I had an idea - what about forming foam (maybe styrofoam?) to make the features I want and then spraying some sort of hardener or body filler over it so it keeps its shape?

I dont want to paint anything on these panels. Just have some aluminum inserts and leather on them.

[Thephranc]

The blue or pink insulation for homes makes a great base for forms. Its cheaper than modeling foam or sign foam like we use ( that stuff is crazy expensive). Cuts easy with an electric knife or hot knife, just watch the fumes. After you shape it you can cover it in some thing like bondo or even use it a s buck for fiberglass. It will melt with solvents for you will need to seal it with mold release or alum foil, plastic cling wrap. On the plus side of it melting you can remove the foam later on so complex shapes are possible. Made some hood scoops that way.

[Barrrf]

YES - FOAM BOARD - thats the crap I keep seeing in my mind but couldnt place where I had seen it. In my own DAMN basement is where Ive seen it (its been covered with drywall for a few years so its not like I run into everyday).