Door panel build thread

[garys 68]

I've seen a few threads on making interior door panels and decided to dive in and make my own.
Well that and the fact new repros for my 72 442 were expensive and ugly.
So this is my first shot at this, so comments/corrections are welcome.
I took apart the old door to find the cardboard backing was disintegrating and the top curved metal support corroded. I'm keeping some of the harware, trim, and armrest to use on the new panel.
So off to buy a sheet of 1/8" pvc.
I screwed the old corroded metal top edge to the bench.

Laid down a 2' x 4' piece of pvc and screwed a wood support just behind where I'll make the bend.
Add heat and bend to follow the contour of the original piece/

Use the old door for a pattern for holes and to make a rough cut of the outside edge.

Screw it to the door, mark the edges, make the final cut.

I'll add a metal lip and felts to the top edge tomorrow. I'm waiting on my christmas tree fasteners.
Oh and a note on cutting pvc. It's a little like radioactive waste or stripper glitter. Once you get some on you, it seems to get everywhere in the house. So vacuum it up as you go.