Dennisrh
True Classic
I had just finished with installing my new AC, sound insulation and stereo system when I ran into a problem (Part I of the Restomod is here http://xwebforums.com/forum/index.php?threads/22951/).
The original door cards would no longer fit properly with the sound insulation between them and the inner door skin. I decided I would make new door cards and reupholster them and the seats as well. The original seats and door cards were not in bad shape so I removed them and put them in storage.
Door Cards
First step was to draw up a template to cut the new door cards with. I used a large piece of cardboard and cut it to the right size and shape and then test fitted it on the door. When I was satisfied that the cardboard markups were perfect I then had to make a decision about what to make the new door cards out of. The options I considered were to use a similar compressed fiberboard as the car came with, thin plywood, fiberglass or aluminum. I chose aluminum as I had recently read about a sound insulation project similar to mine where they used aluminum sheeting as an additional sound barrier in the doors. In the other installation they put the aluminum sheeting between the door cards and the sound insulation where mine would be the door cards themselves. I had recently purchased some aluminum sheeting for the sides of my shed in my back yard and found that the scrap I had leftover was enough to make two door cards with. I don't remember how thick the aluminum sheets I used were, but they were thinner than a quarter and you could bend them by hand, so still fairly flexible. I used a pair of sheet metal snips to cut the basic shape and then a grinder and sander to perfect the shape and size.
My first try at an aluminum door card. I didn't end up using this one because I cut the bottom edge too much and it left a gap. Luckily I had more aluminum to try again.
Unfortunately I didn’t take too many pictures, but I will explain the process the best I can. I shaped both aluminum door cards as perfectly as I could. Each door card had a cutout for the door handle, interior light, door lock and speaker and holes for the armrest. I took the door cards to my upholsterer and he drilled the holes for the clamps that hold the door card to the door. He used heavy duty metal spring clamps rather than the original plastic clamps. The metal spring clamps hold better, but require a thin plier like tool to compress them so they can be removed. I had a set of spare door cards that were very warped and we took the door lock plastic guide off of them. This was glued to the aluminum door card and then the leather covers were made. New door padding was stitched to the leather and then the covers were stretched and glued to the new door cards. I had the leather door covers stitched with the exact pattern that the original doors had to keep the original styling even though they were leather and a different color then original.
Here is the door card completed.
The Seats
I had a spare set of seats that were worn and sun bleached pretty badly. I took the spare set of seats to be upholstered rather than the original seats so that I could keep the original seats and door cards just in case I ever want to go back to all original. Not much to say about the seats except that I told the upholsterer to copy the pattern as closely as he could to the original pattern on the seats.
Edit: Almost forgot about the stuff the upholsterer did to refurbish the cushions. The upholsterer removed the bottom cushion and checked the springs. The springs were fine, but they were cutting into the cushion which is why the seats felt a bit worn out. He placed a semi-rigid piece of material on top of the springs so that the springs couldn't cut into the cushion and then put a layer of material, I think it was vinyl, on top of the cushion to make them waterproof before putting the leather cover on.
Here is what he did.
Back panel redone in black leather.
New floor mats to match.
Restomod part III - Suspension, wheel, tires, exterior - http://xwebforums.com/forum/index.php?threads/23538/
The original door cards would no longer fit properly with the sound insulation between them and the inner door skin. I decided I would make new door cards and reupholster them and the seats as well. The original seats and door cards were not in bad shape so I removed them and put them in storage.
Door Cards
First step was to draw up a template to cut the new door cards with. I used a large piece of cardboard and cut it to the right size and shape and then test fitted it on the door. When I was satisfied that the cardboard markups were perfect I then had to make a decision about what to make the new door cards out of. The options I considered were to use a similar compressed fiberboard as the car came with, thin plywood, fiberglass or aluminum. I chose aluminum as I had recently read about a sound insulation project similar to mine where they used aluminum sheeting as an additional sound barrier in the doors. In the other installation they put the aluminum sheeting between the door cards and the sound insulation where mine would be the door cards themselves. I had recently purchased some aluminum sheeting for the sides of my shed in my back yard and found that the scrap I had leftover was enough to make two door cards with. I don't remember how thick the aluminum sheets I used were, but they were thinner than a quarter and you could bend them by hand, so still fairly flexible. I used a pair of sheet metal snips to cut the basic shape and then a grinder and sander to perfect the shape and size.
My first try at an aluminum door card. I didn't end up using this one because I cut the bottom edge too much and it left a gap. Luckily I had more aluminum to try again.
Unfortunately I didn’t take too many pictures, but I will explain the process the best I can. I shaped both aluminum door cards as perfectly as I could. Each door card had a cutout for the door handle, interior light, door lock and speaker and holes for the armrest. I took the door cards to my upholsterer and he drilled the holes for the clamps that hold the door card to the door. He used heavy duty metal spring clamps rather than the original plastic clamps. The metal spring clamps hold better, but require a thin plier like tool to compress them so they can be removed. I had a set of spare door cards that were very warped and we took the door lock plastic guide off of them. This was glued to the aluminum door card and then the leather covers were made. New door padding was stitched to the leather and then the covers were stretched and glued to the new door cards. I had the leather door covers stitched with the exact pattern that the original doors had to keep the original styling even though they were leather and a different color then original.
Here is the door card completed.
The Seats
I had a spare set of seats that were worn and sun bleached pretty badly. I took the spare set of seats to be upholstered rather than the original seats so that I could keep the original seats and door cards just in case I ever want to go back to all original. Not much to say about the seats except that I told the upholsterer to copy the pattern as closely as he could to the original pattern on the seats.
Edit: Almost forgot about the stuff the upholsterer did to refurbish the cushions. The upholsterer removed the bottom cushion and checked the springs. The springs were fine, but they were cutting into the cushion which is why the seats felt a bit worn out. He placed a semi-rigid piece of material on top of the springs so that the springs couldn't cut into the cushion and then put a layer of material, I think it was vinyl, on top of the cushion to make them waterproof before putting the leather cover on.
Here is what he did.
Back panel redone in black leather.
New floor mats to match.
Restomod part III - Suspension, wheel, tires, exterior - http://xwebforums.com/forum/index.php?threads/23538/
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