Postby slug_dub » Fri Sep 23, 2011 2:03 pm
Paul, to answer your question about the construction... I didn't document very much of it with any photos but I did indeed make new doorcards from MDF. Pulled apart completely the old card and used the fibreboard as a template. Doorcards that don't already have the teardrop speaker grills have a 4" hole for speakers, whereas the teardrops need 5".
I got the thinnest MDF I could find at Bun Buns which was actually 3mm, whereas the stock cards are 2mm. Without wanting to spend a lot of time hunting down 2mm material I just went with the 3mm. It has the melamine coating on one side for a bit more water resistance. Had a drill press to do most of the holes. The MDF is so soft you must use some sort of wood under it when you drill and go slowly like you're routing otherwise it just fragments. I also had to route out a millimetre of thickness around each of the holes for the plastic clips so that they would fit. Drilled out the three metal clip fittings that are riveted to the board and re-riveted them to the new card. Undercoated and painted the card in a gloss coat to help with water resistance.
Although all the clip holes were cut well enough to fit the clips, with the paint on top they were actually very difficult to fit, gave myself a blood blister with the force required! However the doorcards are quite solid and when removing them again I don't think the clips would break before the card.
Covered first in a thin layer of wadding for the padding gluing it to the MDF all over, then the material. I only glued the material to the back side and not the front, so it could be pulled just enough to be taut.
Finally, used a small leather punch to punch through the material at all the points where screws would go through to the front side (teardrop attachment and handles).
Bizi, sorry do you mean the crashpads? Unfortunately I was bad and didn't take any photos of much during construction at all... but I can take a phot of the backside of the completed doorcard. I am not done yet covering the crashpads that go along the front. I covered in suede the small one on the driver side between gauges and door, but wasn't very happy with it and may do it again... complex shape to those.
The American wrote:hella sic stance flushing pard harker yolo something something.