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While looking about for a material to make the inner panels for doors/kickpanels/rear panels I've found a good answer. First was considering fiberglass sheet, 1/8" thick. Instead have found THE stuff: Sheffield Plastics' (should already be a "no brainer" with that name, huh?) "Makrolon" polycarbonate sheet. The piece I got is 3/16"--maybe a bit thicker than the "pressboard" original, but not obvious. The stuff can be easily cut with a Skil saw (plastic cutting blade), It's tough non-shattering and can be drilled, bent, etc. Just finished cutting out two door panels in about 15 minutes. pre drilled all the holes and sanded edges. Plan to use some 100 grit sandpaper on the fabric side to allow contact adhesive to "bite" it and hold closed cell packing foam (from one of those "U-Mail-It" places [Mailboxes,etc. in my case]) to it as a substitute for foam (read: sponge) rubber. My reasoning here is waterproof materials, no warping, mold, rotting crumbly bits.... EVER AGAIN! I've gone to the bother of installing 6-32 "NutSerts" in the places where the steel trim screws went in the doors, to hold panels in place. Stainless screws as well. Now I wish I'd made the "crash-pad" onna dash with this instead of plywood as per original. The pad was made by offering up the plywood to the body, C-clamping in place and marking holes/ part outline, removing and cutting with Skil saw. Drill the holes and mount it back in place for a final sanding/shaping. Then (this is the ~good~ part) gluing a quartered lengthwise section of a swimming pool "noodle" to the wood with contact cement. Shaped the noodle with a 24 grit 2" 3M Rol-Loc disc on a die grinder... covered with a material SWMBO found scrounging thru "Jo-Ann Fabric" store @ 2 bucks a yard. looks for all the world like OEM, folks... and we have mebbe TWO DOLLARS in the whole crash pad. Panels will be a bit more expensive, but better by far than commercially available ones, and a LOT less money. Photos will be assembled soon.
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