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Custom door panels

Posted: Sun May 05, 2019 3:43 pm
by rmel
The door panels on my 712 project truck were totally messed up.

Looked around for replacements, most of the metal replacement
panels are cut from Aluminum Diamond plate which I don't like.

Found a source for several different textured Aluminum and SS from
http://xpressmetals.com/ out of upper state NY. Several
interesting patterns, 6WL, 5WL, 2WL, etc, made by Rigidized Metals Corp.
You can request samples. See attached of samples of 5WL and 6WL next
to Diamond plate. I settled on Aluminum, 6WL, 0.063" stock which measures
in the ballpark of 0.09" inc. the raised texture, fits in the channels well.
IMG_2041.jpg
IMG_2041.jpg (747.87 KiB) Viewed 138 times
I had to fabricate a template from a plastic sheet, as my original panels were
only good for the barrel. This took time, a lot of patience, and numerous
tweaks and to get right. Once that's done you can flip it over and the template
is good for the opposite door. Cutting and fitting the 6WL panel was not too bad.
IMHO the look is far better than Diamond.
IMG_2039.jpg
IMG_2039.jpg (874.78 KiB) Viewed 138 times

Re: Custom door panels

Posted: Mon May 06, 2019 5:20 am
by lifefloat
Wow...…….that door panel looks nice. I run with stock panels but would like to do that "upgrade" someday.

Did you notice any noise or vibration increase now that you have metal there instead of pressboard or what ever the original material is?

Did you use any sound deadening material?

Just curious.

Anyway...........looks real nice.

Re: Custom door panels

Posted: Mon May 06, 2019 10:10 am
by TechMOGogy
Love it - thanks for sharing and YES - looks way better than the diamond plate.
Great find!

Re: Custom door panels

Posted: Mon May 06, 2019 10:22 am
by rmel
As far as noise goes, I "soundproof" my doors. First step in
the process is to remove the goo inside the door itself, then
I apply a vibration damper, followed by a layer of mass loaded
vinyl. You have to cut away some of this to provide a space
for the door handle cup. When it comes time to insert the
metal door panel, I apply some vibration damper on this as
well. When your all done if you hit the outer door or the
door panel you hear only a thud :wink: The drivers door
should be as deadened as possible as it gets the most noise
from the exhaust and street traffic.

Re: Custom door panels

Posted: Mon May 06, 2019 6:43 pm
by VinceAtReal4x4s
Cool find. I like the ABS option too. I did some in textured ABS and the weight savings was really noticeable and it was easy to cut speaker holes into. No chance of any corrosion and very easy to trim up if needed. Living close to a big plastics supplier that can cut anything to any size is helpful too. :)

If you want to get fancy with that door insulation, you'd want to add a 1" layer of melamine foam to the back of the inner panel to soak up some of those mids/upper waves.

Re: Custom door panels

Posted: Mon May 06, 2019 8:09 pm
by rmel
I have the malamine foam in the read doors of the 710K, I have found that
the cavity on the front doors is a wee bit tight for the foam. But it's a real
good idea to use it where you can as you suggest.

Re: Custom door panels

Posted: Mon May 06, 2019 8:20 pm
by VinceAtReal4x4s
Is it the treated (hydrophobic) stuff? Where did you get it? I'm having issues finding any, other than what SSkin is offering under their name Mega'Zorbe, but they limit it to 1/2" which make little sense to me given you need 1" of it to start being effective. I guess they assume people will glue two together? Kind of pricey ://

Re: Custom door panels

Posted: Mon May 06, 2019 9:51 pm
by rmel
Yup SSkin is where I'd go. Yes your right!! You need to double up on
the thickness, 1/2" is not sufficient. Their spray adhesive is really
good to do that -- stack em two high. It's expensive stuff though.