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