Door Card Insert Vinyl Re-wrap - Early Panels (OBD1)

[Twistytee]

I picked-up a couple of Dove Grey door panels from a newer side-airbag car to re-place my original non-airbag panels. I had the infamous vinyl shrinking around the map pockets as well as some damage to my drivers door card. The replacement panels were in better shape with the exception of the driver's insert which has a lot of cracking from the PO using the arm rest.

I kept usable parts from the original panels including the non-airbag door inserts. The price of coupe door cards in good condition keeps going up so I like to keep a stash of usable replacement parts in case I have a future need. The vinyl on my original inserts had shrunk too so I removed them in hopes of a future re-wrap. I decided to tackle it today with the use of some high-quality Landau Top & Trim adhesive. While not a professional job by any means, I think the driver's insert came out well so I intend to re-vinyl the passenger side and rear convertible panels.

I picked-up a couple yards of light grey marine vinyl (#71652939) from Joann Fabrics. I had a 40% off coupon so it was $11.99/yd which is a decent price for fabric-backed marine grade vinyl. It's not the same cream color as the original Dove Grey inserts, but it matches the darker grey door cards well and hopefully won't show the dirt the same way the lighter original vinyl does.

First I stripped the original vinyl off the inserts and sanded them smooth to remove the previous adhesive residue:

Untitled by Twistytee, on Flickr

I did the same with the rear door cards and cleaned them with lacquer thinner. They are made of a more durable molded plastic material compared to the front inserts which are a compressed fiber board material.

Untitled by Twistytee, on Flickr

I chose to paint the front drivers insert in the hopes it would provide better surface prep for the contact cement. I'm not sure this was necessary as the solvent in the contact cement loosens the paint during the application process. I will probably skip it and apply directly to the fiber board for the passenger side insert in the same way the factory applied the adhesive.

Untitled by Twistytee, on Flickr

I used the following DAP industrial contact cement for adhesive. It's designed to apply vinyl tops to the exterior of cars and has a high temperature rating for that application as well as interior trim pieces. Unfortunately the smallest container it comes in is a gallon and it's only available at upholstery supply houses. It's intended to be used with a spray applicator, but it can also be applied with a brush.

Untitled by Twistytee, on Flickr

I used cheap disposable paint brushes from Lowe's and applied to both the door insert and the fabric-backed vinyl. The instructions say to wait 5 to 10 minutes so that it dries prior to bonding the two materials together. I waited about 15 mins due to the humidity. Note the fumes from this stuff are very potent. I wore a a 3M paint respirator with 6001 cartridges. I also used nitrile gloves and worked outdoors.

Untitled by Twistytee, on Flickr

Brushed on door insert and allowed to dry. Note the light grey marine vinyl has been cut and sized to the door insert so that it's easier to apply once the adhesive is brushed on.

Untitled by Twistytee, on Flickr

Brushed on back of vinyl:

Untitled by Twistytee, on Flickr

Applied slowly working right to left - starting with the complex curve to the left of the arm rest area and moving across to the door handle cut-out and the location of the mirror switch. I had a helper hold the vinyl as I worked to lay small sections at a time. I also used a wallpaper trim roller and a smoothing tool to help lay the vinyl flat. I then used an x-acto knife to cut relief strips on the reverse side of the panel insert. This allowed me to fold the vinyl flat along the curved sections.

Untitled by Twistytee, on Flickr

Relief cuts on the rear of panel insert. They're not as "pretty" as the scalloped edges used by the factory, but they get the job done.

Untitled by Twistytee, on Flickr

Factory edge:

Untitled by Twistytee, on Flickr

Finished panel insert. I plan to let it cure for a few days and will then install it on the door card. The vinyl seems to be holding much better than when I tried to repair the old vinyl using 3M Super 77 spray and regular contact cement from the hardware store. There are some small wrinkles when examining it up close but it's a dramatic improvement over what I was dealing with previously.

Untitled by Twistytee, on Flickr

I'll update the thread again once I install the hardware and get them mounted to the door panels in the car.

[bluptgm3]

I'm amazed that the fabric layed into the complex contours of the door panel insert. Nice job!!!
I've been under the impression that the leather/fabric was pre- formed then bonded.

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[Twistytee]

Thanks.

It seems the consensus is it was vacuum bonded by the factory or supplier. That would make sense since it would eliminate/minimize any air pockets behind the vinyl. The old vinyl I pulled off did appear preformed, but hard to tell. When I first tried this with 3M spray adhesive, the vinyl let go overnight. I'm hoping the Landau solvent based adhesive provides a permanent bond and it keeps it shape. Time will tell.

[E36328Coupe]

Looks great. How does the insert detach from the main door panel?

[tiMASTER]

3M super trim adhesive is a similar product and available in aerosol and smaller containers.

Same purpose- used to attach vinyl tops. I used it exclusively when I was recovering amps and speaker cabinets.

[Twistytee]

Looks great. How does the insert detach from the main door panel?

On the early panels, the insert is glued to the door card. I used a heat gun and slowly heated the rear of the door panel while applying light upward pressure to the perimeter of the insert. If you work slowly and are careful with the heat, the glue will release and you can separate the two without damaging them. For the later panels, there are plastic rivets that need to be cut loose in order for the insert to separate.

[E36328Coupe]

Sounds like I have the early ones

Thanks

[Bimmerick]

I picked-up a couple of Dove Grey door panels from a newer side-airbag car to re-place my original non-airbag panels. I had the infamous vinyl shrinking around the map pockets as well as some damage to my drivers door card. The replacement panels were in better shape with the exception of the driver's insert which has a lot of cracking from the PO using the arm rest...

Twisty I can't see your pics; is it me?

[mslevin]

Twisty I can't see your pics; is it me?

Photobucket stopped allowing 3rd party hosting, they're broken for everyone.

[Twistytee]

Yeah. They're going down the tubes quick. Last ditch effort seems to be holding our photo albums hostage and demanding a $399 year subscription for 3rd party hosting features. I should have started using a different host a couple of years ago when their site got so slow and riddled with bad pop up ads. I'll move the photos for this thread over to a different host as I plan to update it when I put the re-wrapped inserts on the panels and reinstall in the car.

[Bimmerick]

Photobucket stopped allowing 3rd party hosting, they're broken for everyone.

Yeah. They're going down the tubes quick. Last ditch effort seems to be holding our photo albums hostage and demanding a $399 year subscription for 3rd party hosting features. I should have started using a different host a couple of years ago when their site got so slow and riddled with bad pop up ads. I'll move the photos for this thread over to a different host as I plan to update it when I put the re-wrapped inserts on the panels and reinstall in the car.

I apologize for the thread hijack, but...

Wow, I had no idea. I have been linking my photos from PB on this forum and others for years. This is crazy. I am sitting here totally flabbergasted; so unless PB "changes their mind" OR I pay $399 a year extortion to PB, basically all my photo links in every forum thread I've ever written will be broken... Terrible business decision; if PB sticks to this policy, they will surely go under.

[Twistytee]

Slowly going through the process of replacing the photobucket links on some of my threads. Note I have not yet installed the refinished vinyl inserts in the car, but the Landau adhesive appears to be holding nicely. The first time I tried this using 3M spray adhesive, the vinyl had already started pulling away within 24 hours of installing. Hope to get these in the car soon.

[MtekJosh]

Slowly going through the process of replacing the photobucket links on some of my threads. Note I have not yet installed the refinished vinyl inserts in the car, but the Landau adhesive appears to be holding nicely. The first time I tried this using 3M spray adhesive, the vinyl had already started pulling away within 24 hours of installing. Hope to get these in the car soon.

I recently did this same thing except used suede on the inserts. Should have seen when i tried to copy the fancy relief cuts the factory made...lol good thing i bought extra!

Yours look great! I restore panels all the time. I have built up a graveyard of like 40 coupe panels I pull parts off of lol so handy

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[tomcoppola]

Reviving a dead thread.. I know.

I've just gotten my door card inserts reupholstered but I can't figure out what product to use to re-adhere the insert to the door card. OP, did you use the same spray adhesive?

[gc325is]

tomcoppola, Nice find, Mine been sitting off the car for 5 years. But as you probably also have the door vinyl is also peeling and the trim cannot sit back flush on the door. But if you are able to put it on flush , contact cement is also good but not as critical as it only needs to hold the panel on not bond it to the fiber board contours.