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How to make door panels out of lexan


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#21 colourbox

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Posted 15 March 2017 - 01:00 PM

Got the arm rest and door clip holes drilled out of the template.

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#22 colourbox

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    Cleopatra Jones

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Posted 15 March 2017 - 01:49 PM

Door latch and window crank holes have been cut out of the lexan.

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#23 colourbox

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    Cleopatra Jones

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Posted 15 March 2017 - 02:22 PM

Came out nice. No cracks ya'll!

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Got it sanded so the glue will stick better.

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#24 colourbox

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    Cleopatra Jones

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Posted 15 March 2017 - 02:58 PM

Two panels!

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#25 colourbox

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    Cleopatra Jones

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Posted 15 March 2017 - 04:42 PM

Next step is to test them out on Stanley before attempting to put the vinyl covering on. I also need to find some foam. Getting to the home stretch!

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#26 thisismatt

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Posted 15 March 2017 - 05:44 PM

Did you radius the front edges?


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#27 colourbox

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Posted 15 March 2017 - 06:15 PM

Not sure what you mean. We traced out the old panel onto the wood template and routed out the lexan using the wood template. Were you meaning something else?

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#28 thisismatt

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Posted 15 March 2017 - 07:06 PM

I mean did you ease the sharp corners (edges) of the lexan so that it's not a hard edge when you wrap with vinyl, either with a quarter-round/roundover router bit or by sanding? :)  Seems like you would want to, otherwise you get a very sharp edge that could be more likely to wear or cut through the vinyl


I'm your huckleberry.

One jump ahead of the lawmen
That's all, and that's no joke
These guys don't appreciate I'm broke

#29 colourbox

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    Cleopatra Jones

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Posted 15 March 2017 - 09:10 PM

Ah. I thought that might be what you were asking but I wasn't sure. Yes, I did sand the cut edges down to smooth them out.

q6qhLgg.jpg

 

When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#30 colourbox

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    Cleopatra Jones

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Posted 17 March 2017 - 06:27 PM

I had to file down the door clip holes some. Just the part where the clip slides into the smaller hole. Tomorrow I plan on putting the vinyl on the new panels. I think I'm just going to use the felt that's on there. Going for it! Stay tuned....

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#31 colourbox

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    Cleopatra Jones

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Posted 18 March 2017 - 12:29 PM

Got the good vinyl covering off the panels and cleaning them up to put on the new panels

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#32 colourbox

colourbox

    Cleopatra Jones

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Posted 18 March 2017 - 01:32 PM

Getting it glued down

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When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.


#33 colourbox

colourbox

    Cleopatra Jones

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Posted 18 March 2017 - 03:58 PM

And they're done. Everything worked out nicely. I used some Goof Off to clean up the 35 years of dirt off the vinyl. If you use it just don't go too far cause the color starts to come off.

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q6qhLgg.jpg

 

When I die, I want to go peacefully like my Grandfather did, in his sleep — not screaming, like the passengers in his car.