Club 80-90 Forums

Here's my door card build.
Old door card off


Back of old door card.

You can see water damage along the bottom where the speaker sits.

Vinyl trim removed.


New High Density Fibreboard (HDF).


Old card stuck to new HDF with double sided carpet tape, the old card is the best template for all the holes.


Off to the trusty bandsaw.


Which does not have enough throat.


Drilling the mirror switch hole (35mm)


Drilling the clip holes (10mm).


Trial fit.


Feather the edges of the board to allow for the carpet.


Give both sides a good coat of thinned yacht varnish.


When it's dry I'll stick some cord carpet on the face and make some new speaker pods.
More to follow.

Good work. This is on my to do list too.

You can buy, for around the £100 mark, a complete set of (depending on preference) either MDF or Ply interior cards with all the holes pre cut. I've pondered this for some time and do have the tools to make my own, but not sure its worth the effort on a full set, but certainly for door cards ply would seem to be more resistant to warping. If the plastic membrane is missing from the doors, this must be replaced also, or door cards will warp in no time. Varnish will help too,

CovKid wrote:You can buy, for around the £100 mark, a complete set of (depending on preference) either MDF or Ply interior cards with all the holes

So far mine has cost me 3€ for each door card.

CovKid wrote:... but certainly for door cards ply would seem to be more resistant to warping. If the plastic membrane is missing from the doors, this must be replaced also, or door cards will warp in no time. Varnish will help too,

Door cards can't warp if they are secured by the correct clips, hardboard was good enough for VW.
The varnish will prevent moisture ingress into the HDF which would be the end of the board.

CovKid wrote: If the plastic membrane is missing from the doors, this must be replaced also..

It is missing and it will be replaced when I source some heavy duty plastic sheeting.

I'm one of the first to offer up money-saving ideas Titus. I wasn't being remotely critical, more practical where it comes to replacing all inner cards. I can see where you're coming from in being able to preserve the interior. Very tidy job.

CovKid wrote:I'm one of the first to offer up money-saving ideas Titus. I wasn't being remotely critical, more practical where it comes to replacing all inner cards.

I knew where you were coming from mate so no worries.
I am only making them so that I don't have to do something with the new clock installation.

Titus A Duxass wrote:Door cards can't warp if they are secured by the correct clips.

I would like to disagree

My door cards are held with original clips and they have warped due to a previous owner removing the inner membrane

Also around the bottom near the step they have began to crumble

Thats it youve convinced me to make my own now. I was gonna get a set from newton. But budget is starting to get tight now. Dont know if youve seen that mega stretch carpet from mvm but it moulds very well, I was thinking about doing some slightly raised detail panels just to make em look a bit more one off if you get my drift

I wonder (in some respects) if a plastic based door card (covered) is not a better replacement. Something more like thin chopping board material that would act as a membrane too on the reverse. Thin ply would be my choice but I'm a great believer in reducing weight on the vehicle where practical to do so - without compromising any strength. Decisions, decisions

That's something I have been thinking about Ralph instead of wood, but I'm guessing the price for such material would be much higher. Need to look around for suitable sizes.

Agreed, thin soft plastic would be perfect.
3 or 4 mm would be optimum but I've never seen anything at a reasonable price in the size required.

Something like this maybe?

http://www.ebay.co.uk/itm/3mm-PVC-White ... 1768wt_918" onclick="window.open(this.href);return false;

Part II
The Speaker pods, I've seen these at shows all over the place - thought I'd have a go a making my own.

Template made.


Template glued to a piece of junk ply and then cut out with the band saw.


Pods roughed out in MDF on the bandsaw.


Template screwed to roughed out pod and then shaped on the router table.


Circle jig on small router to cut out for the speaker.


Nice fit!


If you use MDF you get a lot of dust - wear a mask and have a good dust extractor.


Edges rounded over on the router table.


Nearly finished.


Just got to seal them with epoxy resin and then decide on the covering - carpet, leather or paint them in the same colour as the bus.

Impressed with your workmanship on those pops Paul, they look great

Cheers Micky.
Having the correct tools helps a lot.

I was just about to slap a coat of epoxy on them when I realised I had made two right hand pods - doh!

Good job I some spares.