Inlay Style Trunk and Door Panels - Need Help & Ideas - Lateral-g Forums

The WidowMaker · #1 08-13-2012, 11:58 PM

im going to be starting the interior on the chevelle and need some help figuring out how to build the panels. id like to do an inlay style panel (1st pic below) and have an idea on what id do, but id rather not reinvent the wheel and end up with a longer process on top of it.

my idea is to start with a template of the inlay piece. with this, i can use the router and bushings to cut a hole in a 3/8" piece (the main panel) and cut another piece to inlay out of 1/4". since the 3/8" piece would be cut all the way through, i would need some sort of backer to attach the inlay to with (velcro?). for this, id just use a piece of 1/8" mdf that i would bond to the back of the 3/8. in the end, i would end up with a 1/2" thick piece of mdf with a 3/8" deep cut and a 1/4" piece to inlay in the hole. i thought of starting with a 1/2" piece, but i dont want to route all the inside out to 3/8" deep.

the questions; is there an easier/better/faster way to do this? what gap should i leave between the inlay and the hole? my thought was 1/8" all the way around which would probably end up at 1/16" after putting leather on it. im also thinking that the 1/4" inlay with fabric folded around its edges and back plus the velcro will make it stick out the extra 1/8" to be even with the 3/8" deep cut. is this an accurate assumption? is there something better than the velcro to fasten? what sort of glue should i use that i can spray from a gun? ive read that landau (sp?) is good, but cant find it in anything less than 1 or 5 gallons.

second issue. for the rear shelf i need to build up the depth a little to mount my speakers. they will also be in a cut out section and have an inlay of speaker fabric or some sort of grille over them. since i dont want to run a full sheet thats 1" thick, i want to build up the edges around the inlay and leave the rest of the panel thinner (kind of like second pic). whats the proper way to do this. ive thought about cutting my own mdf in the shape and size i want, but that too is tons of work. hagan street rods sells a foam that will do the same thing (3rd pic), but its expensive and im not sure its the size i want. are there other foams like this? any other suggestions? Clint, Tracy, i'd love your opinions! Thanks!!!

70 chevelle · #2 08-14-2012, 07:19 AM

Instead of using mdf why not glass over a foam core . Mdf door panels are going to be heavy.
foam
http://www.avtcomposites.com/cgi-bin...&category=1230

The WidowMaker · #3 08-14-2012, 11:33 AM

ive never worked with glass or foam before. it would be a great option if the foam was hard enough that i could work it like the mdf. it would be a lot tougher since i dont know how much the glass would add to the thickness etc when doing my cutouts and i dont know how much detail i would lose.

i could always build them out of mdf, make a mold and then lay my parts in glass. id get the detail, wouldnt have to worry about build thickness, but that would be a TON of work.....

70 chevelle · #4 08-14-2012, 11:51 AM

Are you building your own panels to save some cash or because you don't like the look of whats available? If it's to save some cash .. you won't. Between materials and trial and error you will spend much more than you think. I could have easily just bought a set by now. Too late, I'm in too deep. Making the molds reqires a disgusting amount of time.

The WidowMaker · #5 08-14-2012, 12:30 PM

mostly because theres not really anything available. i talked with marquez the other day and they seem to be at least another year out. plus, with my tubs, seat belt mount and harness bar, i have to cut up the panels some anyways. and i have to build a dash. i might as well learn the simple stuff before taking on that friggin project.

if you were to make yours again, how would you do it (besides buying

)? im thinking of doing the door panels in just a thin sheet of mdf with an inlay as well.

70 chevelle · #6 08-14-2012, 12:41 PM

I would do the base the same . Make the shape out of the foam I gave you the link to. Glass over it and body work it. Given how well you have done the rest of your car I don't think you will be happy with the weight of an mdf panel.

The WidowMaker · #7 08-14-2012, 04:14 PM

thanks tony. i'll look into the glassing a little more. how do you think they are making the raised areas and the depressions? it appears they are glassing over something, but what is that something?

how many layers of glass for something like this? any other quick glassing pointers?

70 chevelle · #8 08-14-2012, 07:40 PM

I have some foam at the shop. I ordered it it to start on my package tray but have not been able to touch my car in a while. Are you in a rush? Give me a few days. I'll see how well it routers. I dont think there will be any problem routering it. As far as the glass itself it depends on the shape you come up with. Panels with tight corners are going to require something different than a straight panel.

RECOVERY ROOM · #9 08-15-2012, 06:41 AM

1/8 and 1/4 Landau foam would work for your needs. Check a shop in your area that works on vinyl tops.

The WidowMaker · #10 08-15-2012, 04:47 PM

tony, whenever you get around to it. im looking at starting some time next week though.

Quote:

1/8 and 1/4 Landau foam would work for your needs. Check a shop in your area that works on vinyl tops.

tracy, thanks for your input. i'll give them a visit and see what they have. will those foams be hard enough to use with a router? im finding this in 1/8 and 1/4" rolls so im thinking its going to be too soft for a router. how would i get a nice uniform edge that rolls into the cut out section?

depending on what i end up doing with the mdf, ive found that my 3 main trunk panels would weigh between 8 and 12 pounds total. not extremely light, but ive taken a lot of weight out. the 12 pounds would be with 1/2" frame and 1/4" inlay.