Make your own door cards

[andyk_79]

OK so I've been reading up on working with masonite with the thought that I might have a crack at making my own door cards in as close to OEM style and finish as I can achieve.  There's plenty of resources out there for other makes BUT they all have a straight door lining rather than the fold/bent one that the 240Z has.  I've been reading up (mainly on model train sights) on methods for bending masonite without fudging it/breaking it and I think it can be done.

 

When I actually get round to attempting this I'll post photos and a step by step but in the meantime I wonder if anyone has attempted this before ?

 

What I'm thinking of doing:

 

• Cut masonite to size, using the old cards as a template (and with a bit of trial and error)
  
• Using a method I've read up on where you VERY lightly score the masonite where you want the fold to be, lightly dampen it and apply gentle pressure over a long period (it'll be a slow process - will probably have to rig up a vice somehow), then repeat the dampening and pressure until it is the required shape
  
• Drill/jigsaw door handle hole and clip holes etc
  
• Any sanding smoothing of edges
  
• A few coats of a marine grade sealant - I want these things to last
  
• Cover using either a purchased covering kit (about $200) or head to Spotlight, get some vinyl and thin foam and have a crack on the sewing machine
  
• Fit it up!
  

 

The masonite, sealant etc should come in under $50 from Bunnings.  Even if I use the covering kit it's worth the effort when a set of Nissan door cards is now over $600 USD

[d3c0y]

I have some good nick door cards i want to sell if you are ok with speaker holes in the front? They are black though.

[andyk_79]

Black is fine (same as current).  Once I've got the car back I need to take a better look at the condition mine are in but definitely might be interested!!

[andyk_79]

Even so I still may have a crack at this if I run out of other jobs to do on the car (chances of that happening on a 42 year old car = ZERO!!)

[phillay]

interesting... i might have a crack at this next weekend I didn't know the material is called masonite.

[gav240z]

The Masonite is the part you need. You can get reproduction vinyl kits with the chrome strip and all it is just shaping the Masonite.

 

It might be easier to form out of fiberglass instead and unlike Masonite won't warp from moisture.

 

However and not to deter you, but like many things you'll find you may only save a few bucks by the time you go to all this effort and it may make $600 sound reasonable.

[nizm0zed]

Dont the doors have a bow in the centre of the panel, eg, the sides of are still all one reasonably flat panel?

 

Edit: added pic.

 

You'd almost be better off making a press for the masonite.

Make a buck and plug mold shaped like the panel and then sandwich the masonite between them.

Just wet it then add weight to the top of it, maybe 1-2 kg? let gravity to the work for you.

 

If you designed it right, you could do FG skins off the mold, so you could cater to the original type bloke wanting something factory correct, or you do FG for the guys that want to go lightweight or strong.

[Six_Shooter]

A mold for fiberglass and a form used for masonite are made very, very differently and would not lend themselves well for the alternate process.

 

Any commercially availble masonite I have seen is much thicker than the door cards and would not only be heavier than the original door cards, but difficult to work with. Most door cards are a pressed cardboard type material that is much lighter than masonite.

 

If/when I get to making my own door cards I will be using a plastic that (where I work, an upholstery shop) uses for interior fabrication. It's light, easy to work with, forms well with heat, it's waterproof and can be bought in many thicknesses, or layered to form shapes. We've nearly stopped using any sort of wood based product for large flat panels anymore because of how well this plastic works.

[andyk_79]

I completely forgot the shaping at the trailing edge !! Yeah I can see it would be a ridiculously complicated task to get that shape right. For some reason I had it in my head that there was only one fold.

[phillay]

hey six shooter, do you know what is the plastic material called?

[fluegel]

Is there any difference between  door cards on a 2 seater and a 2+2. I have been thinking of making a mold for my door cards which which are 2+2. I had an idea to use thick cardboard and wet it then clamp it on a mold. After it is dry you could saturate it with west system epoxy to stiffen it. This may work although the heat moldable plastic may be better.

[skipz]

I thought this looked doable.  PVC door cards as an alternative to fibreglass or masonite.

 

http://www.classiczcars.com/forums/interior-s30/25007-door-panels.html

[gav240z]

Is there any difference between  door cards on a 2 seater and a 2+2.

 

Like the doors they are longer than the 2 seater ones. They also have a handle for the rear passengers to open the doors in the upper rear section. Which the 2 seaters don't have / need .

[gav240z]

FYI: I was interested in this, but looks like the group buy fell on it's arse.

http://www.viczcar.com/forum/index.php?topic=12110.0

 

I've since managed to find 2 good pairs of OEM door cards so right now I don't need a set myself, but as I mentioned on that thread I'm not a huge fan of the masonite because most door cards these days are pretty average at the bottom due to water damage. You can also relatively easily get the vinyl skins which could be mounted on this kind of card and would obviously be more durable.

 

No photos.

http://classicdatsun.com/new/240_interior.html

 

Photos

http://www.datsunparts.com/Z-Car-Parts

http://www.datsunparts.com/2334

 

 

However once you add all this stuff up, the OEM ones at $600 odd (before shipping) - start to seem quite reasonable

[gav240z]

Kameari do FRP backings - which would look good without the trim (if originality doesn't matter?)

 

http://www.buyee.jp/item/yahoo/auction/q30467872

http://www.buyee.jp/item/yahoo/auction/q30331452

 

Not exactly cheap, but could be a good mould to make more fiberglass ones from? - Which could then be covered.