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I finally got some time to resume working on this old door panel. I want to test fit the panel to the door before covering the panel. Other than getting the overall shape and size of the door panel right, the other most critical part to making sure the door manel fits is getting the slots for the door panel clips in exactly the right spot. If the clips don't exactly line up with the holes in the door shell, you will not be able to attach the door panel to the door.
I used a big piece of craft paper as a template to transfer the location of the holes to the back of the door panel. The location needs to be precise in order for the door panel clips to align correctly.
The "craft paper" ended up being too flimsy. I couldn't be sure where exactly those holes lined up on the door panel using that thin craft paper. So back to the drawing board.
Next I use a little bit heavier stock of paper that I cut to the exact shape of the door panel.
I reinforced the paper with some cardboard so it wouldn't be so flimsy. Believe it or not, this made it much easier to handle and to position on the door.
I put the paper door panel on the door exactly where the real door panel will go. I used a pencil to mark where the holes for the clips are. I also marked the holes for the armrest and poked the window crank and door pull through the paper. Lastly I marked the four screw holes that go in each corner.
Now I carefully laid the paper door panel on top of the replacement door panel and transferred the marks I made with the pencil onto the actual door panel. I used a black sharpie to precisely mark each location.
Using the black Sharpie marks as a guide. I laid the door panel clip on the door panel and marked where I think the whole should be for each door panel clip to attach to the door panel (Six clips toward the leading edge of the panel, four on the rear). Note, there's an offset between where the door panel clips slides onto the door and where the clip actually passes through the door shell.
I followed the same procedure for all ten door panel clips, the holes for the arm rest screws and the large holes for the door pull and window crank.
While the door panel is off, I cleaned the bottom-inside of the door. There was plenty of dirt/gunk at the bottom partially obscuring the drain holes. I also inspected/cleaned/lubed the window and lock mechanisms. Now I can reattach the plastic water shield to the door shell. The factory used some spray adhesive, I used some dum dum (3M strip caulk).
Next up the big springs that go over the door pull and window crank shafts. These go between the door shell and the door panel and push the door panel out so they don't sag inwards. Now the door panel can be attached to the door shell. I found it easiest to start at the door jamb end and pop the clips on starting at the one closest to the bottom and working my way upwards. Hint: always make sure you have the next clip lined up before popping a clip into the hole.
Here's the prototype door panel backing board all buttoned up on the door.
At least I know the shape is accurate, and now I have a good template for making the passenger side. Next I'll have to see about covering with some padding and some good vinyl. Not sure what color, I kind of want to recreate the factory look vs a monochrome look.