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240 Cardboard Door Panel Repair

Stiggy Pop

Stiggy Pop

In the cool kids club
Joined
Feb 27, 2011
Location
Granville, MA
I can't be the only one who keeps finding door cards with punky rotten cardboard at the bottom. Does anyone have tips or experience repairing or salvaging these? Anyone remade them somehow with new material?

Thought so far is to cover the door in wax paper, soak the door card in fiberglass resin and let it dry in place to get some shape and strength to it again. Interested in hearing what others may have done.
 
most times I've seen door cards redone, it was masonite from HomeDepot, or 1/4" ply, 5 coats of shellac on both sides and then glue down some quilt batting and fabric.
 
I used the semi rotten panel as a pattern to drill holes in some heavy nylon sheets that were note book dividers. Thin plexiglass available at a big box hardware store would work. Cut them down to about 4 inches wide and 11 inches long. Double holes to allow insertion of snap fastener and retention in the smaller hole just like the original fiber card. Brushed off some of the loose fiber to allow the fasteners to fit into the holes. Cut the vinyl inside cover behind the map pocket to insert the sheets toward front and back between the fiber padding and the card and snapped it into place.

Cut in the interior vinyl completely invisible.

 
cwdodson88 said:
most times I've seen door cards redone, it was masonite from HomeDepot, or 1/4" ply, 5 coats of shellac on both sides and then glue down some quilt batting and fabric.
Click to expand...

Redoing the whole panel like that or just a bottom piece and attaching it somehow? The factory cardboard has some shape to the mold - does a big flat piece of material work out?

Testpoint: a "support" piece like that is a good idea as well.
 
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