Page Comparison

Functional Requirements:

• Allow for easy access to and operation of the interior handle / latch

• Should not touch seats or other components of the car

• Should not interfere with opening/closing of door

• Lightweight: should not be too heavy for hinges to handle

Non-functional requirements:

• Aesthetically pleasing

• Easy to manufacture

• Should not cause injury if bumped against (want rounded edges, soft material)

There’s a surprising amount of youtube video of people diy-ing their own door panels

https://www.youtube.com/watch?v=qr9CGT3BQGo

Materials

• PVC foamboard and ABS plastic sheets seem to be the most common materials

https://www.hotrodders.com/forum/interior-door-panel-material-393769.html

https://www.hotrodders.com/forum/abs-vs-pvc-66825.html

List of benefits of PVC foamboard

1. is completely waterproof.

2. is easily cut, shaped, drilled, and sanded with regular wood working tools, and there are no splinters.

3. is easily stapled, accepts contact adhesive with no problems, can be heat formed, sewed, and glued together.

4. will never warp, rot, or absorb liquids.

5. is completely smooth, and tough enough to allow you to install and remove your panels numerous times with no problems.

6. is lightweight (1/2 the weight of solid PVC and 2/3 the weight of ABS)

7. is less expensive than solid PVC and ABS. One $30 sheet of PVC foamboard should do your door panels and kick panels, which also makes it less expensive than waterproof panel board and about the same price as good quality luan plywood.

Things to look out for

• Excess heat can warp the plastic: as in leaving the car out in the sun can cause issues.

  • The package tray (horizontal surface right under the window) is especially prone to overheating: might be best to use plywood on those surfaces