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.