Building Custom Door Panels

Trim the door and cut a 3 to 5 degree bevel on the lock side of the door.

Building custom door panels.

Building a show quality interior to match the rest of your build can be a daunting task. But using some readily available components you can achieve professional looking results. Dry fit your door mark for any trimming to be done. A table saw makes that easy.

Dry fit again mark the center of your lockset center of the existing strike. The simplest method is to use the miter gauge that came with your table saw. Attach a straight 24 in long hardwood 1 3 for more accuracy and to avoid splintering out the end of the cut. Mark simpson demonstrates on a 1962 oldsmobile door panel how to create custom car door panels using abs board and pre sewn top stitch panels from ez boy interiors.

Building new panels also gives you the option of using higher quality materials. When removing the old panels be sure to remove all staples and hang on to the clips used to hold the panel to the door. However with a little instruction and a broad selection of car interior upholstery parts the task is made easier than you might think. Measure your jam and mortise the hinges.

Install the lock and you should be done. To build a square door the stiles and rails must all be exactly the same length with perfectly square ends. The door frame is built using loose tenons or dominoes with a panel that floats in a groove in the frame. This film will teach you how to design construct and upholster your own auto door panels.

For most classic car restorers sewing together upholstery is an unlearned skill. I build mine by laminating two pieces of 3 4 thick stock. This series of videos will walk you through building custom interior door panels. Step 1 place one 48 by 48 by 1 8 inch hardboard on a worktable.

Design your custom door using any wood species glass texture size or shape. Clamps clamps and more clamps interior doors are usually 1 3 8 thick. Interior doors interior panel bifold doors interior barn doors interior french doors glass panel options redi prime.