This project was started a couple months ago. It's still in the works. It's a little more costly than just using cardboard but I wanted something that would last and wouldn't break. Between work and rainy weekends progress keeps getting interrupted. I've got a spare set of door panels to mess with until the lexan is ready. I was able to get the covering off the spare panels. Not too difficult since the glue holding it is 35 years old. I'd like to reuse it on the lexan. Making panels from lexan and reusing the old vinyl is going to be an experiment I hope works out.
Here's the old door panel
Stripped off old vinyl material. It just pulled right off.
Used the old panel to trace out a template on a thick piece of wood. Used a router to cut the shape.
This is the sheet of lexan. It's been cut down into 4 pieces.
Next my husband and I plan on taking the template to his dad's place so we can use his drill press to drill out the door clip holes and holes for the arm rest screws. Plan on doing that this week.
That's where I'm at now. Going on vacation next week so won't get back to this for a couple weeks. Once we get back to this we'll be using the template to route the lexan into shape.
Has anyone ever made door panels and glued in foam between the panel and material? I'm thinking I'd like to do that instead of just gluing the material to the panel. Can anyone recommend some glue for the job? We've got an idea of which will work best but I'd like to hear other people's experience.
So I've been wanting to try this for a while and I actually wish I had known of this sooner....like over 20 years ago sooner. Might've saved me a lot of days nearly bursting into flames driving in 100 degree weather in a car with no a/c. I still love you Stanley
You've probably seen these in youtube videos and you may have even made one yourself. I've decided to finally stop procrastinating and freaking make one already. I got a styrofoam cooler, a PVC elbow and a fan that can be plugged into the cigarette lighter. This here was just my tester to see that this actually has potential. I think it does. After I got it together I tested it out in my Pathfinder and after a few minutes there was a noticeable difference. To see if this was actually working, after it started to feel cool, I turned off the fan and it would get warm. Turn the fan back on and it would start to cool again. So tomorrow I do this for real on a 48 qt cooler. I'll list what I used and show you step by step how I made the cooler. Til then, here's my prototype.