by Mark Sennott

Created on: July 24, 2009

This article is not about how to fabricate custom fiberglass car door panels. Molding fiberglass is a much more complicated job than just installing a custom fiberglass car door panel and is not recommended as a casual DIY. Previous fiberglassing experience is a must. If you are working in an enclosed space, wear a mask and make sure there is adequate ventilation. The fumes from fiberglass and epoxy are dangerous. You will also find that fiberglass dust gets into everything and is difficult to vacuum up completely, although cut fiberglass is still much less messy than the leftovers from epoxy and fiberglass. If those drip on anything, it is there forever.

Instead of all that, this article assumes that you have been to a good custom shop and already have your custom panels, or that you are planning to get them. You just need to install them.

Roll down the window before starting.

Remove all the screws or fasteners holding the old door panel in place, beginning with those at the top. These are usually found at the corners of the panel, around the door and window handle, and anywhere else where something is mounted on the door. Their exact location varies slightly from model to model.

You can save the screws in older models. In newer models, the factory clips are not designed for more than one use. You can get new plastic rivets from an auto supply store or hardware store. The fit will be snugger too, which helps keep the door from rattling. Bring in your original fasteners for matching.

Remove the door handle, window crank, power window control panel, and all other door mountings. In some models the handle and door lock are attached. In this case, unclip the rod from the lock and remove the handle and door lock together.

Remove the old door panel. If the panel does not come off easily, you have missed a fastener somewhere. Be careful not to damage the door mounting.

Fit the new panel into place and attach the fasteners, starting from the bottom. It is easy to accidentally snap a door panel, so take it easy on this step. Make sure the new door panel is at the right angle before trying to fasten it. If you have to force it or if any part of it is bulging, the angle is off.

An easy trick to get a factory fit for your new door panel is to use the existing factory door panel as your base. Cut out the inside of that panel until all that is left is a 2-3 inch frame, retaining the side and bottom factory mounts. Design the custom panel to fit the inside of the original panel.

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