The first pic shows the panels with almost all the holes cut. The one on the right has several small holes cut in an attempt to lighten it up to the same weight as the original cardboard versions. I only managed to shave off about 50 grams and the aluminum versions weight about 300 grams more than the originals. I'd cut more holes or larger holes, but I had concerns about the foam and vinyl not sticking properly.

 

The next pic shows the passenger side door panel installed. It fits perfectly! Perfectly after I trimmed it about 10 times! I got my original pattern off of a junkyard door that was less than perfect, so that explains that. More pics coming if you guys are interested.

 

how r u going to finsh them , engine turning, polish, paint . ?

 

I believe that answers it

 

Looks like you did a great job getting your pattern down and cutting everything cleanly.

How come you chose to work with aluminum rather than a plastic?

 

aluminum is gonna be a very cool set up, cant wait to see the rest

 

Thanks for the compliments. I had considered using reinforced plastic (circuit board material) instead of aluminum, but I thought it would probably be cost prohibitive. I didn't check on that though. I never considered using plexiglass because I think it's too brittle. I also ruled out fiberboard because of the possibility of water damage. As for the finish, I'm thinking of using leather, vinyl, carbon fiber, or all three. I'll probably stick with something pretty conservative for my design theme. That's in the works as I write this. I'll be sure to post pics when it's finished.

 

Looks great so far. Are you going to use the original upper molding peice with the window sweep? Also wouldn't using metal produce some nasty rattles?

 

No, the original upper molding pieces were bent (lower in the center than on the ends), so I bought replacements from Year One. As for the rattles, vinyl or leather will be wrapped around the edges onto to the back side of the door panel. That will take care of the edges. As for the center, I plan to adhere foam onto to the back side of the panel to take care of any other rattles.

 

Ah, that is a great setup you got going there then. How much did those moldings from year one set you back. I need to pick up a set sometime.

 

They were $139 a set. Kind of pricy for less than perfect in my opinion. But, since there aren't any other options, what can anyone do?

 

Looks good, when you put the foam on the back side pay attention and don't make it so that it restricts the movement of your lock rods, or your power locks if you have them will have trouble.

 

It's been a while since I even had a chance to think about these door panels. I decided not to use them. I tried pretty hard to lighten them up by punching a series of holes in them, but they're still heavier than the originals. I decided to keep them as templates, but I will probably fabricate some out of fiberglass or carbon fiber instead. If that doesn't work out, I will just use fiberboard. Honestly, it's not like I run my car at the track or anything, so a couple pounds probably doesn't really matter that much. I'm setting it up for pro touring and the thicker fiberboard would probaby dampen some road noise anyway.