Custom Door Panel Help
 

Can someone point me in the right direction with how to make custom door panels for my 70 nova? I love the look of the marquez and fesler stuff but 1100 dollars for door panels is a bit out of my league (not to mention they dont make it for my car anyway) and I would like something to keep me busy.

Do i use the original window felts? Do i make them out of foam then make a mold of it or something?

Any help would be greatly appreciated.

--Jeff

Now I was looking around a while ago & found this post, but the pictures are now missing, but the comments make it seem like it turned out well

http://www.stevesnovasite.com/forums....php?p=1167395

My dad does upholstery work and he suggests on these cars that you start with the upper metal part off factory panels (I see it's mentioned in the last post in the thread). On some cars that wouldn't apply, for example I think early mustangs are basically a flat panel with no upper part that covers up that ugly area at the top. For a Nova, you'd want to start with the metal.

I believe he uses Luan board then foam and then the materal, already sewn into whatever pattern. You can use less or more foam in areas to give it dimension or to account for things like the door handle/window cranks, and also in the area for an arm rest.

For something closer to what the aftermarket has you'd probably build up a complete mold out of hard foam (like the green garden foam), on top a door. Basically building a mold for the panels. There are a lot of fiberglass websites that detail how to create a mold that you can use to make a part. You'll understand why the aftermarket fiberglass door panels are priced the way they are pretty quickly this way.

I'm not trying to discourage you but by the time you make your own masters and then take molds from them you will easily reach the costs these guys are asking for panels. I wish someone made panels for chevelles when I stared on mine, I may have saved money . Unless you get it perfect the first time there will be wasted materials and alot of trial and error. I have too much invested to turn around now. This may help your decision.
https://lateral-g.net/forums/showthread.php4?t=10123

wow guys, thank you so much for the responses. this is way more of an undertaking than i could have ever imagined and definitely makes me realize why such panels are priced the way they are with out a doubt. though, it is nice to be able to say you did it yourself. i may give it a whirl but my have to bow out and fork up the money when the time comes.

amazing work. i may have to PM you with some questions when the time comes to start working on my own if that's ok.

Feel free. I would be glad to help.

do a search on youtube and see how the custom shops are making panels. if you dont plan on making a bunch, i dont see a reason to make molds. plus, if you want a stock style its pretty simple and wont take up much time.

for the more advanced stuff, most guys are making a base panel out of mdf and then stretching fabric over that panel in the areas they want depth. put a little resin on the fabric and you have a pretty stout piece. cover that in a thin layer of foam and then stretch your final material and youre close to done.

it still will take a LOT of work if you want a detailed part, but it can be done.

im definitely only planning on making one set. i just figured making the mold would be smart if needed to replace one or something. I guess now my question would be how to attach it to the door without having exposed screws or stuff like that

70 chevelle is the man and has given me some advice and many ideas with his pictures. hopefully he will chime in with some answers for you.

but, i still dont see the need to worry about replacement panels. making a mold is a crap load of work and i just dont want to invest that much time. my basic frame will be mdf with a lot of material removed to save weight. then im going to do as i said above and just stretch fabric over it and apply some resin. i will probably come back and do a little glass work on the back to reinforce some areas. the goal is to do it with the least amount of sanding possible.

all of this will be negated for me if marquez comes out with their chevelle interior in the next 4 months or so.

Tim

thanks tim!. 70 chevelle is the man with those panels. I would love to see how youre going to do yours. maybe start a build thread with pics of the panels. I think i might use your route to avoid the molds becuase the more and more i think about it the more i feel like i need to listen to reason and not make them. I just want a modern look very similar to feslers stuff or in this case 70 chevelle's . :thumbsup:

I'm making my own for a '72 Olds. I'm using he blue foam you can buy at Lowe's with epoxy resin and glass mat.

Shiny Side Up!
Bill

thanks Bill!...ill definitely be checking that out.

--Does anyone have any info on mounting the door pulls and the actual panels themselves for that matter?

The door pull will need to mount in some way that is directly attached to the door, and not just the door panel. When I made the armrests in my father's '56, I used a 90* bracket that attached to the door, the armrest then slid over that, then the pull (a cup style) mounted down through the armrest to the 90* bracket.

As for attaching the door panel, I plan on using the stock christmas tree style clips along with a set of screws down under the door panel. These will be concealed by their position under the bottom curve of the panel, as well as by covers.

Shiny Side Up!
Bill

beautiful. thank you, Bill! I really appreciate the info.

same goes to all the others that have contributed thus far. Im always overwhelmed by the wealth of knowledge here.

Thanks guys:thumbsup: I'm definitely no expert. The reason I made the molds was soley to vacuum bag the parts which made them lighter and stronger. I wanted sealed air space for midwoofers , I could not find a way to do this with mdf without the panels being stupid heavy. My car will not be a feather weight when its done but I simply refused to make 50 pound panels.

If your just making a specific shape and have no need for a double walled panel, I'm sure you can make some from mdf that would be a reasonable weight. As for mounting the I 'm using screws through the door pull hole and speaker access. If you look at the pictures the door pull screws directly to the mount which attaches to the door itself. Your never actually pulling on the door panel itself. the panel could just mount with screws but I did not want it to vibrate so the outer perimeter has the same material used to mount an Ipass to your windshield . Its strong stuff.

There is an interior thread on here started by the recovery room where he shared a few tips abut making the base panels from aluminum and how to mount them. There work is simply incredible and picking his brain would be the best thing you did.

thanks tony! for not being an expert, your work definitely says different. thanks for all the advice, its much appreciated.

Check this out--
http://www.pro-touring.com/showthrea...l-build-thread

Me, myself...I'm going to buy the Fesler one's for my Chevelle. I've paid for a custom set of door panels before and they cost waaaayy more than $1100. About time you buy all the materials, pay for the labor and then pay for the upholstery you will have quite a bit of money in them. I think the Fesler one's are perfect for the price and they really look good. Although, Fesler doesn't make them production yet for your Nova check with him anyway. But, any custom stereo shop or custom upholstery shop can make them.

The Shop Llc Interior Build Pics
 

CLICK ON THIS LINK AND CHECK OUT JOSH AND NICKS 70 CHEVELLE, I POSTED OUR DETAILED INTERIOR BUILD FOR 70 CHEVELLE MAYBE IT WILL HELP YOU OUT.......GOOD LUCK IF YOU NEED ANYTHING GIVE US A HOLAR.....
THANKS.....THE SHOP LLC

http://www.hubgarage.com/mygarage

we are buying some new tools to make more interior stuff so we can make them faster and for a better price. I am working on all of this stuff now so check back with me. I have a 70 here that we did so designing a door panel for it is easy. I just have to buy the tools.

bitchin' i love the looks of your door panels and if its the bagged silver nova youre referring then im on board. I didnt realized what an undertaking and costly affair this would turn into. rather than save money it would probably only aggravate me. lets see how impatient i get and see if i still want to make my own becuase of the great info from the other members on here. Thanks for teh reply. love the rest of your stuff and cant wait till i can get some funds to buy the hood hinges and trunk hinges!

thanks. excellent info on here. thought this thread had died but thanks for bringing it back!

great point. i do love teh fesler stuff. never lets me down when i see what they do. im still on the fence about designing and building my own. im sure by the time i pull my hair out trying to figure it out how to do it ill be ready for fesler to step in.

thanks for the reply. I was just admiring this chevelle the other day and fell in love with the dash work you did. the whole thing especially the interior looks phenomenal. amazing work!

EDIT: I guess someone already posted it.....but I'm reposting it. :D

Bill check out Gary's custom 1972 442 door panels he's making out of 1/8" PVC.
I'm going to follow his lead and go all black in my metallic green 70 442 tribute.
To the OP this is something you should also check out.

The costs for this design are VERY VERY minimal.
Materials are under $100. Totally demystifies the whole daunting task.
His inserts are covered with vinyl carbon fiber and chrome tape found in most parts stores.
Very simple to accomplish and the end result is pretty damn nice IMO.

http://www.pro-touring.com/showthrea...l-build-thread

http://i18.photobucket.com/albums/b1...t/DSCN0224.jpg

Check out his dash too, he dumped the faux wood vinyl overpriced junk and put the vinyl carbon fiber over it as well.
I totally dig it.
http://i18.photobucket.com/albums/b1...t/DSCN0208.jpg

I LOVE THIS CHEVELLE's INTERIOR!!!!!

I called the shop in Fort Lauderdale that allegedly did the interior work. I never got a hold of anyone. Who did the dash and rear seat ?!?!?!?

PM Me the details if you can, I've been trying to find out
what this cost, or if they can make another dash!!!! I know the buckets are Corbeau LG1's from what I can tell.

ARE YOU SURE YOU CALLED THE RIGHT SHOP? WERE STILL HERE CALL US UP........954-825-8395 THANKS A TON FOR THE GOOD WORDS............ http://www.hubgarage.com/mygarage

THANKS A LOT FOR THE COMMENTS, YOU CAN CHECK OUT MORE PICS ON THIS LINK........THANKS AGAIN http://www.hubgarage.com/mygarage OR WWW.HUBGARGE.COM AND GO TO SEARCH THE SHOP LLC 954-825-8395

that was the project "inmotion" car correct? id be interested in some info on prices on a dash like that as well. its the nicest ive ever seen. i plan on either using the marquez stuff when it comes our or making my own. this would add a third option.

thanks, Tim

Thanks for the good words Tim, Were currently in the process of manufacturing and mold making for the Chevelle 68-69, 70-72 I do have another dash almost ready to go.......Pricing varies on electronics and various options which we provide for various builder wants and needs......Gimme a holar Tim.....Thanks again Clint "THE SHOP LLC"
954-825-8395 http://www.hubgarage.com/mygarage www.hubgarage.com/mygarage/CLINT

Clint - you nailed that dash inset. It's different and cool....:thumbsup:

Thanks Ron, were constructing a few new dash pieces will post em up as soon as we get a little further in the finish work......(65 Gto, 69 Camaro,57 Ranchero, Nova).....
http://www.hubgarage.com/mygarage www.hubgarage.com/mygarage/CLINT WWW.THESHOPLLC.COM CLICK ON GALLERY

heres the fixed link. you may have to register.

http://www.hubgarage.com/mygarage/CLINT

SIDE SHOT WITH CONSOLE COMPONENTS, AUTO METER, VINTAGE AIR, ELECTRIC LIFE, ALPINE www.hubgarage.com/mygarage/CLINT

WWW.THESHOPLLC.COM CLICK GALLERY

Nice work guys..!!!

Wow!! Thats a killer looking dash! Are you guys making a kit to replace the whole dash? Or just the insert with all the guages? Thats some nice work!

i just talked to clint today and they are making a whole interior kit in addition to the full dash. sounds really good. there will be more to come in the next couple weeks!

Tim

Awesome! Can't wait to hear about it!

Thanks a lot Tracy, The past year and half we've really been work'n on some new stuff......Now were just trying to get it on the street......And as always great work on your guys end.....Thanks again "The Shop LLC"