Door panel inserts

[XploreNV]

When I bought my Patrol, they were missing the door panel inserts / door cards. The other day I made a template for them and drew them up on cad. Today I found my extra sheet of 1/8" stainless and decided to cut them out on the water-jet. I think they came out pretty good, I'll try to install them some time this weekend to verify fitment. I didn't put the screw holes in them so I'll have to just drill them to spec, but once I do that I can add the screw holes into the cad file.

image-46.jpeg

[zed]

Considering using plastic sheeting behind the inserts. This will add a vapor barrier and also minimize any abrasion marks created by the metal-to-metal contact.
Keith

[XploreNV]

Good idea Zed. I can cut these out of anything, I just had this stainless laying around. Originally I wanted to use a nice stained wood, but was scared the water jet would shred the edges. I still might try a particle board and wrap it with fabric. I'd just have to use something to seal the particle board before cutting it so that it doesn't end up totally soggy and warped from the water.

[RiverPatrol]

Nice job.

You might not want to include the screw holes in the template. They are different for every truck. I think they're drilled on the fly when the panels are installed.

[XploreNV]

I had a feeling they might be different from Patrol to Patrol. Most vehicles from this era have major variations from vehicle to vehicle. I know Mustangs from this area have panels with a tolerance spec +/- .5" , meaning they can vary up to an inch on these panels which seems ludicrous to me on a unibody vehicle.

[miller]

Looking good mate. Any chance you could share that file?

[XploreNV]

Yeah, no problem! The first run I made needed a bit of trimming on the big piece. I'll go in and edit the file so that it should be a perfect fit before sending it over. Should have it done within the next few days. I'll email it to you as soon as it is done

[miller]

That would be so great. Thanks heaps!