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I too my 1991 Firebird door panels apart and am planning to clean and keep the original fabric, but replace the foam inside as well as the gross cardboard panel that gives the panel its stability.
I found a shop online here in Germany where they can make custom 3mm thin plastic panels from a DXF file.
The question now is whether anyone of you might have a true to scale schematic of the cardboard piece that I could use to convert the image into a DXF file myself - or if maybe anyone even already has a door panel DXF file somewhere.
I am also planning to use strong 1cm x 2cm magnets integrated into the plastic panel instead of the push pins. Shouldn't be too hard to replace the original push pin locations with fitting rectangle holes to glue the magnets into.
If i had a door card from a Firebird, I would gladly layout a dxf. Unfortunately I only have door cards from a 83 Camaro.
'83 Camaro should be the same as far as the outer shape and holes for grab handle. Only thing that may change slightly is the upper cutout for the door latch handle.