I had originally modified and installed the 4th gen door panels from a camaro. I noticed a large gap at the bottom, and being the stupid perfectionist I am...lol, I had to change it. SO, I have decided to fabricate 4th gen "style" door panels using a template from the 3rd gen door panel. I'll post pics when I'm done, but for now, just waiting for the resin to cure, so I can reinforce it with fiberglass mat. Basically what I have done so far was this:

1. Made a template for the door panel
2. I then hacked up the 4th gen panel to get the features I wanted, like the top trim piece to mold well with the 4th gen dash and the door handle piece, because I put 4th gen door handles in.
3. Mocked up everything on the door and made sure nothing rubbed or interfered
4. Built a speaker pod for a 6 1/2" component speaker set. I wanted to be a little original, so I took the door locks and window controls out of the door panel, and put them in the center console. In place of the controls, I put the tweeter for the component set. Looks pretty cool, especially flush mounted, plus it's angled at the driver and passenger, respectively.
5. (The step I'm on now) Fiberglassing each piece, such as the arm rests, speaker pods and the such. I'm not sure what material I want to cover it in, or just give it that "glassed" look. I'm thinking the "glassed" look would probably be better, since I did the same thing for the dash.
6. Not quite sure where this project is leading, but I'm sure it will turn out well....lol...probably more money, time, and headaches...lol.

Oh...I'm waiting on the Kenwood DDX-7015....I enlarged the stereo pod to handle a double din receiver...and moved the heater controls to the center console. I am planning on putting the receiver and a navigation system in place of the old stereo and heater controls. Again...I'll post pics when I'm close to finishing and when It's finally done.

If you have any questions or comments...let me know...critiques and suggestions are always welcome

 

No critique or questions here... just encouragement

I kept wanting to do this exact same thing, but never got around to it ( too many other projects half way through right now lol).


If you manage to get it to look right, post a writeup on it

Good luck!

 

I just finished fiberglassing the door panels and let me tell you...they seem more sturdy than the old 3rd gen door panels I had. When I made the template for the door panel, I used the existing holes for the retaining clips. I also added 4 to the top of the panel near the window trim. Now I have to sand them down so they are nice and smooth. I love the look of them so far. They are not as long as the 4th gen door panels, and I am trying to be a little more creative with them. I did not incorporate the map pocket or the lower carpeted trim. I'll try and get some pics up by this weekend. So far it has been a lot easier than I thought it would be. I'll try and keep this post updated. As always...if you have any suggestions or comments, let me know.

 

Sounds like an interesting project. Cant wait to see some pics of it!

 

This sounds cool, I would like to see pics as well.
Kory

 

Hey man post up so picts! I love to see this kind of custom creativity!

 

These are the best ones I have so far...just remember...it's still a work in progress. I still have to sand them down, finish fiberglassing a few minor pieces and the such. I like the 4th gen "style" I think they turned out pretty well so far.

 

One more pic

 

Nice! Where you able to just lay the fiberglass over a 4th gen panel, or did you rip apart a 3rd gen panel, and a 4th gen panel, and combine them appropriately?

I'm new to the fiberglassing thing, so feel free to go in depth

 

Well...Basically...i just used a large piece of very flexible, very thin cardboard and made a template for the panel. Once I got the template layed out so that it fit perfectly...I made the appropriate holes for each of the retaining clips. I drilled 4 new holes at the top of the panel just to give it a little extra strength. I tried to use the original retaining clips, but found they were a little too small, so I went down to the local auto paint shop and ordered some new ones that are a little longer. While I had the panel off, I replaced my door lock actuators, lubed up everything, and made sure the window worked better than before.

Then I took 2 pieces of 1/8 inch panel board and stapled them together. I traced the template and cut them out, that way they are mirror images of each other. To get the 4th gen style, I cut up the panel and removed the door handle piece. I don't have a lot of experience with fiberglass, in fact this was one of the first things I have done. I found out that fiberglass resin will not stick very well to aluminum foil. SO, I wrapped the 4th gen upper trim piece in foil, layed a little resin down, and then fiberglassed the mat over that piece. At the same time, I fiberglassed the door handle piece into it. The door handle piece is the only part of the 4th gen panel that is actually in the door panel. I then removed the controls, fiberglassed the opening and cut out an appropriate hole for the tweeter. I did the same thing for the armrest.

Once all the pieces were fiberglassed, I mocked them up with the panel on the door, secured them in place, then placed polyester fleece over the whole thing. Polyester will retain it's shape when you put resin on it. It is very flexible as well, so you can get great looking curves. Well...that's as far as I have gotten so far. Once the final layer of resin cures, I have to sand them down and then prime and paint. The process I used is basically the same process you would use to make subwoofer boxes or pretty much anything else you want to fiberglass.

 

Oh...the "blue" thing is the crossover for my component speaker set. I painted both the crossover module and the speaker grills with that "chameleon" paint. It goes from red to blue. Pretty cool little addition in my opinion.

 

Cool, sounds fairly easy enough


What all fiberglassing things are needed to do this? I was in the parts store the other day and looked over the fiberglassing stuff but didnt know exactly what was needed in order to do something like this.

There was like fiberglass matting or something, then there was a liquid, and a hardener or something, I guess I'm sorta confused?


Do you lay the mat down over the template, then apply your fiberglassing liquid (whatever it's called?) that has the appropriate amount of hardener in it so it's not too runny so that the matting will harden up?


Or am I not even close and thinking of another subject all together?

Thanks for answering these silly questions lol.

 

basically....when you fiberglass something, the mat only gives it a form...the strength comes from the resin. Most people in the audio world use polyester fleece, because it can be molded and soaks up a lot of resin, to make it super strong. Let's see, you will need some fiberglass resin, hardener (usually comes with the resin), fiberglass mat, cheap paint brushes, mixing container, sandpaper to scuff up any plastics that won't adhere resin, masking tape, aluminum foil or cling wrap. It's pretty straight forward. Take your time whatever you're fiberglassing and don't try to do too much at one time. Lay down 1 or 2 layers...then let it cure for a little while, then while it's still a little tacky but not wet, lay down a couple more layers. If you let it dry completely, you'll have to scuff up the fiberglass to adhere another layer. Finally, make sure to follow the directions on the hardener, don't add too much thinking that it will set up faster. All that will do is make the resin more brittle. Any questions I'll try to help out with whatever I know or have learned.

Templates or molds make a lot of different projects much easier. I used molds for the arm rests and the top trim piece. I simply took the 4th gen panel, wrapped each piece in alumium foil and fiberglassed over it. Once I was done with that, the 4th gen piece could be removed and voila, you had an exact copy of what you wanted fiberglassed.

 

I have finished sanding the door panels down and now they are ready to be primed and painted. I just called a local auto customizer, who did my parents PT Cruiser. He is going to paint realistic flames and a Firebird logo on the door panels. I am going to have blue realistic flames painted on the upper piece near the door handle and the firebird logo with realistic flame wings on the lower corner. So far so good. Can't wait to get that part done and see how they turn out.

 

I wish I was good with this kind of thing. I have fourth gen SS seats in my car...and the door panles just do not match at all. I've always wanted a aset of 4th gen panels...but I heard they wont fit with the 3rd gen dash. Definently post some pictures when you get them back from being painted

 

any updated pics?

 

Its not really related, though it is somewhat, but does anybody know the best way to find fourth gen camaro parts? Ive only so far looked at craigslist and junkyards but the junkyards have camaro parts that are messed up beyond repair. Where should i look to find a dash and console and door panels? Thanks for your help and sorry if its not related.

 

camaroz28.com message boards(classifieds section), ebay

 

thanks dude.

 

or try the classifieds on here, there are a few people parting out 4th gens usually