I've been avoiding these door panels for about 2 years now, Moving them here and there, trying not to damage them further. So it's time to put some thought into bringing them back into a state that they'll look acceptable in the 65. There comes a time where you get tired of not having them, and they obviously would finish things off a lot better. Impossible to find (and no, I'm not doing SMS panels), there is no other practical way forward except to try rescuing them in some way.

So as in most winters, I'll try to make a post on how I'll do it. And with some good input and ideas we'll see how it goes.

As they sit, the carboard has gotten wet, and the drivers door has suffered most, the board getting quite warped, and the metal top sill has separated from the board. Same deal overall with the rear drivers side. there is some evidence of black mold on the cards as well. The top vinyl sections are wasted on all 4 panels and the fuzzies are iffy, maybe still usable, the embossed sections below, remarkably are pretty good with some cracking on the drivers lower corners. The chrome Mylar has come away from most of the wide trim strips. Most of the "nails" on the back are still intact and the metal wrap around strips are good.

The plan;

Soak the cards on the most warped panels with a water/mild bleach (for mold) solution, them sandwich them flat under some super heavy weight and let them dry over time.

When dry, apply some waterproofing to the cards.

Carefully, with a straight line, cut away the old upper vinyl along the top of the trim strips.

Remove the fuzzies from, then clean up and re-attach the upper steel sills to the cards in some way.

Glue new thin foam or padding to the uppers.

Apply new vinyl over the uppers, tucked slightly under the old trim strip.

Re-attach the window fuzzies.

Thoroughly scrub clean/degrease the panels. Fine scotchbrite to de gloss. Apply adhesion promoter, paint the panels less the trim strip. I know the colour I'll use.

Apply and burnish bright aluminum adhesive tape (which I have) along and into the trim strip. 2K satin clear the entire panel. I tried a small section, and it works.

Apply a possible trim cover strip along the new vinyl/trim cut.

New door lock ferrules.

I'm open for suggestions guys, please feel free to comment. This one is new to me as well and I need the help.

As they sit,

Probably the best panel. You can see the original colour at the door handle position,

Top metal section removed, a view under the trim strip. The top panel has little crowns that pass through the panel, and get flattened down.

Some lower cracking,

Ugly,