Door Panel Repair (pic heavy)

[Stereoinstaller1]

Since this is an E34, I though I might post a pic or three of a car I did a while ago.

Typical E34 door panel failure, only worse than most I have seen:


Split the vinyl, used a heat gun and contact cement (on a small paint brush) to reglue the stock vinyl back in place. I should have gotten a shot of it, but my hands were all sticky!


I do not know if someone tried re-gluing this panel or not, but I had to use heat, rubbing and goof-off to get the residue off this panel!

Next, I cut some panels out of masonite. I used a 1/8" material, but it was kind of a pain in the butt to work something so thin. Of course, I made a cardboard template first, then a "master" to make the panels from.


I drilled holes where I wanted the studs that will mount this panel to fit:


Countersunk, glued, backnutted and then filled with spot putty, then sanded (120 grit on a D/A) in preparation for upholstery:


Next was upholstering the panel. I have no pics as that is the easy part, really. Just normal "double stretch" vinyl and Dap brand Landau top adhesive in a $10 spray gun.

After the panel was upholstered, I mounted it using the previously drilled holes, washers and nuts (just hardware store crap: bevel head machine screws):


Then (DUH, right?) I cut off the excess studs. These trim panels will never be removed, ever.


So, flipped over, all the glue residue cleaned up:


Just in case you care, here is the rear deck before and after I reupholstered that, too:




I did the headliner, the A, B and C pillars and the rear deck all in a nice headliner material. I pulled the foam backing off of the material to do the rear deck and the pillars (plus like the panel that covers the sunroof motor) but mostly I wanted you guys to see my idea of how to permanently fix the E34 door panel.

I am gonna do my car in all black with brushed aluminum trim. I think Di-NOC will do nicely. Hell, it is a 20 year old car, right?

Luke

[Supra330Xi]

this is a great write-up...I wonder how much this would cost at an upholstery shop?

how do you keep the plastic clips from breaking off when you remove the door panel? Mine usually crack and I have to reglue them back on

[yorkermiles]

Would you do the same with the back door panels as they are smaller?They do come off a lot on cars.
Nice job,very inspiring

Ignore that ...my mistake..just looked

[E34x2]

Nice write up. I did something similar for the loose inserts, I used blind nuts and nylon screws. What material did you use for the rear deck and where did you buy it? Can it be had at a fabric store or does it need to come from an upholstery shop?

[Stereoinstaller1]

this is a great write-up...I wonder how much this would cost at an upholstery shop?

how do you keep the plastic clips from breaking off when you remove the door panel? Mine usually crack and I have to reglue them back on

I cannot even guess what an upholstery shop would charge.

I did most of the interior, it looked a zillion times better.

I charged the guy about $900. I also did a sub box and an amp (that is what I actually do, this upholstery stuff is just something more for fun) and that was another $600 (plus gear), so he dropped about $2000 total.

The car was really low miles, like 65,000 or something, so he is into this really nice clean great sounding full feature car for like $6500. It might not sell for that, but he built it to own, not to sell.

As far as those mounting tabs, I popped all of them off and re-glued them. I used windshield urethane, they are solid like you cannot believe!

[bblazen]

Nice def going to do this over winter.

[Paul G]

Nice write-up. Thanks for posting this.

[Paul G]

Nice write-up. Thanks for posting this.

[89 bimmer]

How much experience do you have doing this? I have these exact panel problems in my 535, and the back deck cloth is coming off, and just sitting on top of the deck. Also, do you have any experience on doing interior for a sun roof? If I could get these 3 things fixed my car would be in FANTASTIC condition.

[zubbie]

Great work.

Off-topic. What's with all the double posts lately?

[89 bimmer]

Great work.

Off-topic. What's with all the double posts lately?

It's my evil plot...

[zubbie]

It's my evil plot...

Then it's a conspiracy cause it's in many threads with many posters

[89 bimmer]

Then it's a conspiracy cause it's in many threads with many posters

Go big or go home right?

Actually Matt mentioned something about it the other day, and I think there might a be server lag.

[Stereoinstaller1]

How much experience do you have doing this? I have these exact panel problems in my 535, and the back deck cloth is coming off, and just sitting on top of the deck. Also, do you have any experience on doing interior for a sun roof? If I could get these 3 things fixed my car would be in FANTASTIC condition.

LOTS and LOTS of experience: I have been a professional car stereo installer (high-end, BMW specialist) for 30 years.

Right now I am working from my home until I change careers.

[89 bimmer]

LOTS and LOTS of experience: I have been a professional car stereo installer (high-end, BMW specialist) for 30 years.

Right now I am working from my home until I change careers.

Could you rate it on a scale of 1-10. And please tell me if I can't do this, or it's a bit advanced. I'd rather be told no without investing than spending a few hundred and realizing I can't.

[E34Kevin]

Nice job! Where did you buy the new fabric for rear deck and headliner? and what glue did you use?

[Stereoinstaller1]

Nice job! Where did you buy the new fabric for rear deck and headliner? and what glue did you use?

Actually, any local "Upholstery Supply" house can get you adequate material. I got these materials from Perfect Fit/McDonald. There was one close in on the eastside, like 10th and burnside area in SE PDX, but I heard it moved.

The glue I used on the roof and the doors is "DAP" brand "Landau Top Adhesive", about $25/gallon, and I spray it with the cheapest harbor freight $10 spray gun I can get.

On the pillars and rear deck, I pulled the foam backing off the material and glued it directly. I needed a very light but sticky spray, but it had to be clear. I tried 3M and a couple of others (I swear, gimme the old school high VOC stuff anyday!) and finally settled on Elmers brand Spray glue...from WalMart!

Could you rate it on a scale of 1-10. And please tell me if I can't do this, or it's a bit advanced. I'd rather be told no without investing than spending a few hundred and realizing I can't.

Only if we can seperate the "hassle factor" from the actual job.

HF on the doors is about a 6
Difficulty is about a 4.

HF on the rear deck is about a 2, but difficulty is about a 5.

Headliner is about a 9 getting the stupid thing in and out, but as long as you have a couple of people to help, taint no big thing.

Overall, here is what I say: find spare parts, hack the crap out of them and see what you can do. Be patient, look for ways you can do it easier/better and do not be afraid to get the supplies you need.

I love seeing good DIYs, so nice to see a guy or girl learn a skill!

Thanks for all the nice comments.
Luke

[yorkermiles]

What material did you use for the headliner?any more pics?great post

[Stereoinstaller1]

What material did you use for the headliner?any more pics?great post

It is a foam backed semi-open weave textured cloth.

I do have a couple more pics, but I suck at teh cameraz.

[leonpiper69]

how di you get all the old masonite off? i tried to remove mine (no luck) and i can not get all the masonite off!!!! i think i ruined my panel.

[Stereoinstaller1]

how di you get all the old masonite off? i tried to remove mine (no luck) and i can not get all the masonite off!!!! i think i ruined my panel.

This car had the masonite falling off, literally only like a few square inches were still glued from all 4 panels!

If you can leave the edges (like 1 1/2") alone, you can cut the masonite off by cutting through the masonite and the vinyl, the peeling it off (with like pliers or something) but only out of the center...and please tell me you are practicing on a spare panel!

Don't forget too, anytime you are working with vinyl, you MUST have a heat gun. Mine was $15 at Harbor Freight and it is fine for this kind of crap.

Luke

[leonpiper69]

no spare (no guts no glory right!!!). and mine is glued down good all over the large section. the tail end just fell off. but the large section, all i could get was small chips off of it all the way around. i think its fubar.

[Stereoinstaller1]

no spare (no guts no glory right!!!). and mine is glued down good all over the large section. the tail end just fell off. but the large section, all i could get was small chips off of it all the way around. i think its fubar.

sounds like a pain in the butt. I would use a putty knife to get a couple inches around the outside, then cut out the middle.

Good luck!

Luke

[fullswing]

subscribed and bookmarked! thank you luke

[gcb]

no spare (no guts no glory right!!!). and mine is glued down good all over the large section. the tail end just fell off. but the large section, all i could get was small chips off of it all the way around. i think its fubar.

that's the pattern i see in mine and all e34's i saw while shopping.

the large front-bottom part glued, and the small long top part peeling off.

mine even have the damn wood in the trim broken... i'm looking for a new panel at junkyards soon. until then i have to use some cheap tape just to hold the flapping thing.

i curse the previous owner every time to let that get to that point... and to use silicon glue and silver tape.