*New Door Panels Not Fitting*
 

I'm back on my door panels since I have a lot of time on my hands due to the Covid-19 pandemic. I bought some 1/8" Hardboard Tempered Panel at Home Depot and got one panel cut. I drilled the holes a little over-sized so the panel would float a little to line it up. Ran into a problem. The panel is hitting the door remote at the handle and the rod causing the panel to buckle a little at the top right and making the door handle not work very well. The spring now will not return the door handle back to it's default position. I checked the thickness of the original black board panel with calipers and it is 5/64". Not much difference in the 1/8" thick panel I have. I tried adding 1/8" washers behind the panel but still to tight. How did you guys remedy this issue when making your own door panels???

Re: *New Door Panels Not Fitting*
 

I can think of 2 options.
1: Use a thinner more flexible material, like kydex or aluminum. I made mine out of .032 aluminum.

2: Modify the regulator so the bar sits n the channel. It can be done, I just don't remember the process.

I'm sure some others may have a better idea.

Re: *New Door Panels Not Fitting*
 

I appreciate the reply. Even if the rod was in the channel the regulator at the handle sticks out to far. That's what is causing the buckle in the upper right portion of the panel. I have shimmed the panel out so the door handle works but still have the buckle. I'm sure there are some other work arounds.

Re: *New Door Panels Not Fitting*
 

The easy way to modify the regulator and arm is to swap sides with the door latch regulator. Then flip it so the rod will sit in the channel like it is supposed to. You will need to shorten the arm. Just cut and reweld it to fit.

Re: *New Door Panels Not Fitting*
 

When Chevy reversed the door handle rotation direction (49?), they just let the remotes rub. That works okay for those flexible factory panels, but not for the stiffer panels you are using.
Get some 47-48 remotes that run horizontally in the recess, or modify some '65 C10 remotes like I did below.

Re: *New Door Panels Not Fitting*
 

Thanks for the replays. I just modified both remotes a few months ago and got them working great. Don't have a welder. Can the remote be turned upside down so the bar fits in the channel? I think I have them shimmed out and working pretty good. It passed my 3 point inspection process......the wife, the wife, the wife.

Re: *New Door Panels Not Fitting*
 

I would try something different. Take your current panel and cut it to clear all the mechanical parts, so it fit flat on door. Now make another panel same size as first panel and glue together. Your panel will be about a 1/4" thick but should lay flat.

Re: *New Door Panels Not Fitting*
 

I appreciated the idea. That is something to keep in mind. Not sure if my window and door handle would fit using 1/4" panels but something thinner could be used. There is always more than one way to skin a cat ☺

Re: *New Door Panels Not Fitting*
 

oldman3,

That was a great idea. I cut a clearance slot for the remote bar to operate. With all screws tightened up (no washers added behind the panel) and the arm rest in place it operates smoothly. The round head where the bar fastens onto the remote is flush with the panel. I don't think I'll need to add anything on top of the panel as once the 1/2" pad and leather are secured to the panel I don't think you'll even notice anything. I'm a Happy Camper ☺

Re: *New Door Panels Not Fitting*
 

jim (oldman) has done this a couple times, his input is great! he has a door panel how-to somewhere on the site

Re: *New Door Panels Not Fitting*
 

sharing your experience and knowledge is what this is all about, great to see, and nice fix.

nice looking truck also

Re: *New Door Panels Not Fitting*
 

Thanks for the comment on my 49. Yup.... this site is great. Sometimes others help me with fixes and sometimes I work it out myself. Glad this is working out as I was not wanted to buy 47 or 48 remotes and starting over again. Can't wait to see how the panels come out. My wife thinks her sewing machine will double stitch the leather in white as the seats are. We'll see. Not sure when I will get around to covering them. I bought some 1/4" staples for my Arrow stapler but they were to wide. Dang the bad luck ☺

Re: *New Door Panels Not Fitting*
 

Glad it worked out for you, nice job...Jim

Re: *New Door Panels Not Fitting*
 

Zippy where did your center console come from?

Re: *New Door Panels Not Fitting*
 

I had to modify it a little to fit.

https://www.classicindustries.com/product/hh6871bk.html

Re: *New Door Panels Not Fitting*
 

Great looking door panels. Are the seats from a nova?

Re: *New Door Panels Not Fitting*
 

Seats are out of a 2012 Ford Focus Platinum. Full leather.

Re: *New Door Panels Not Fitting*
 

I have my Ford Charcoal material ordered but it's taking it's time coming from CA. Don't like gluing the material on the door panels so I bought some 1/4" staples. I wanted to use 1/8" staples but can't be found locally. The 1/4" staples go through the panel so I'll have to figure something out there. Maybe add a shim. I wanted to use 1/4" foam but can't find anything but 1/2" locally. These door panels are fighting me the whole way. I'm hoping the material I ordered is the same color that was pictured.

Re: *New Door Panels Not Fitting*
 

Finished my new door panels today. The material I ordered online did not look like the pic. The material was way to light. Ended up buying some soft black material from Jo-Ann Fabrics local. The wife couldn't get her sewing machine to sew straight so we did do the stitching. Turn out fine.

Re: *New Door Panels Not Fitting*
 

Zippi, 2 questions:
1. What did you have to modify for the console?
2. What are the seats out of?
Thanks

Re: *New Door Panels Not Fitting*
 

I built a box the same width and length as the bottom of the console (box height depends on how high you want your console) and used wood screws thru the bottom of the console to mount the console to the box. I covered the box with the same carpet I have on the floor. The seats are out of a 2012 Ford Focus Platinum. The drivers side has power.