Series 2 to Series 1 Door Card modification

[Bones28]

Hi not sure if anyone is interested but this is my post. Just getting round to sorting the door cards out tonight bit late but who cares.

 

So old door card

 

Removed metal seatbelt supports.

Drilled and cut rivets with wire cutters.

Then I made a cardboard template luckily the rivet holes are there in new door card for positioning.

 

Oh blade used as ruler.

Left my dremel as home long way back, I will have to try with a hack saw.

More to follow.

Ah this will do.

 

Point of no return.

Edited January 15, 2016 by Bones28
Update

[Bones28]

Bit of trimming to do.

 

I am amazed it looks good trimming and bodywork are not my thing.

Not looking forward to the next bit.

Edited January 16, 2016 by Bones28

[Baz]

Nice work :)

[JeffTT]

Well done there, done many of these over the years and it does get easier to do, but rather it be a conversion between series its more a UK / Jap conversion, well on earlier cars anyhow, the real tricky bit is the slot where the seat belt passes through the door card half way up at the back, lucky there is a plastic section to help cover the cuts.

 

Jeff

[Funkysi]

Nice! I'll be doing this shortly as I want to retain the belts on the doors.

[Bones28]

Ta my no more nails glue seems to have worked on the top door mount.

 

 

Started cutting centre slot.

 

[groover]

The slot is in the wrong place lol, the plastic cover utilises that screw on the end there

[Bones28]

Nope have to drill another hole in upper part.

[Mondo]

Sorry, Bones, but you've just ruined that doorcard by cutting the seatbelt slot in completely the wrong place!! :(

 

Edit: actually... I'm not sure....

Edited January 16, 2016 by Mondo

[Bones28]

Only copying other door card

 

 

Test fit.

 

Edited January 16, 2016 by Bones28

[Mondo]

Yep, my bad - I completely forgot there was a slot above the fabric section! Oops!!

[Bones28]

Final gluing. I will have to get some more door clips out of the 20 I have only 4 are re useable so will replace all.

 

 

Now I have to do the drivers side wish there was only 1 lol.

Edited January 16, 2016 by Bones28

[AndrewG]

You can strongly bond the riveted metal brackets to the doorcard fibre material by treating the area with Ronseal wood hardener

and then using epoxy adhesive (or similar). The wood hardener soaks into the fibre rather like fiberglass resin and mat and dries

to provide a stable surface for the adhesive to bond to.

[Bones28]

Drivers side is cut just need to fit the metal brackets.

 

[groover]

My bad too lol, of course you need the slot for the seatbelt to pass through the door card into position :thumbup1:

 

I changed mine to UK panels and moved the seat belt to the Pillar, so been a long time since i had Jap door belts lol

[Bones28]

I had one on top of the other making sure I did not mess it up. 1 shot only, so pleased I did it in the end.

[Bones28]

Passenger door card back on looks ok not perfect but neither am I so we make a good match.

 

 

Drivers side next if only things were simple, both covers with the second hand interior I purchased were broken too.

I will be sorting my drivers window as well have a bad rattle that's driving me mad. I have the part to fix it.

 

[Mondo]

Looks good, that - well done! :thumbup1: