Wanted to share.....I've just finished reconstructing the door cards in my 91 TA Vert. They were the originals, and had seen better days. I had replaced the top black plastic rails when I first bought the car, but the holes in the door cards were long ago blown out, so it was an effort in futility. Additionally, I was replacing the carpet in the car, (Interior color is Beechwood, but the Window Sticker says Camel,) so I ordered a yard of 9205 Cognac to redo the door panel carpet. (It was the closest color I liked.)
I got the Door Card blanks from the now closed upholstery supplier around the corner from my place of business for $18 a piece. (She still has some, so I'm waiting till she shows up so I can buy more.) Modified the new cards using the old ones as templates. All the vinyl, metal trim and binding easily removed from the old door cards and was in good shape, so the upholsterer friend and business associate of mine was able to resew and reinstall everything on the new cards including the new carpet pieces.
To make sure the holes for the studs and Pal Nuts for the upper rail never blow out again, I glued and "soft riveted" (red circle,) a strip of zinc sheet to the upper back side of the door panel, and drilled the holes for the studs in the rail just large enough for the raised hexagon of the pal nut. When it came time to install the rail I just used a small deep socket and tapped the pal nut on tightly with a hammer. The rails are tight, and won'





t move.

 

Very nice work. I want a set of those door cards too. Does she have more than two? Will she ship them? PM me any info.
What did you do about the stitching going thru the door card? Did you just glue the material to the new card?

 

Looks great!

 

Great job!

 

Thanks.....
At this point in the state of her business, I'm not sure if she still has any, and I doubt she'd ship......but you can get them here: https://www.automotiveinteriors.com/...-p/cowl-dp.htm

As far as the stitching going thru the binding and the carpeting, it's not a problem with a commercial grade, industrial, upholstery grade sewing machine with the right needles and thread. My upholsterer's wife is the one that does all their sewing, and she said it wasn't a problem at all. As a matter of fact, if you look at the attached picture where I've added the red lines, this is all new stitching on the 33 year old binding that I reused.

 

I saw that, but thought you ripped the stitching intact thru the old door card. As seen in your last pic. Thought maybe you glued the material on the new card. Great work.