Thinking about doing some aluminum door panels since mine in my 83 are pretty trashed. Anyone have any info on this? Or pics of what they have done? Any input appreciated.

 

You're taking about the inner [usually vinyl/cloth] door panels right not the door skins?

I would'nt go with aluminum panels going to be dangerously burning hot in summer and cold in winter... especially out there on the plains of ND...

using your existing panels as a basic template you can fab some new ones out of 1/8" hard board that should allow you to use the factory clips... if you paint it with some Varithane liquid plastic to seal it it should last near forever... you can wrap the skin with some marine vinyl or cloth of your choice using a 3M spray adhesive. If you are doing a thin foam padding make sure you use the foam safe adhesive some of them will eat foam...

hope this helps

 

Found these on Google image search:




http://www.xtremezuksoffroad.com/ind...at=1&limit=all

http://www.studiotimecapsule.com/aluminum_fabrication

http://coolfj40.stores.yahoo.net/doorpanelsfj40.html

Honestly I would make my own aluminum or plastic door panels, just need to trace the OEM door panel, cut out hole for latch and window crank.

 

another great material for custom interior panels is FRP, like the kind used in commercial kitchens and restrooms.

typically we see it in white, but some manufacturers make it in beige and black, even red.

you can cut it easily with a router, snips, or carpet knife, and the black has a texture which would match anyone who's bedlined their floors, like so:




here's a vendor with some color samples:
http://www.frpshop.com/liner-panels-c-3_4.html

 

mcmaster.com

 

This took me about 20 minutes:


Edit: couldN't find these earlier but a buddy of mine makes these, from his build thread on pirate:

 

Thanks for the responses. tj884Rdlx I checked out that website and I ordered some of the black since I am going to bed line the floor of cab. Thanks for the idea I appreaciate it. I like that diamond plating too but that FRP stuff is cheapppp.

 

Here is some I found awhile back. Just thought I would post for others that maybe looking.

http://www.designsofsteel.com/ABSDoorPanelsTOYOTA.htm

 

that's very interesting.

the downside i see for that product is A) the ABS plastic will be more susceptible to UV degradation than FRP, and more likely to crack from an accidental boot kick; and B) pretty steep price when you compare to a 4x8' sheet of FRP.

still, someone's providing a service with a hand crafted product. could be good for someone in the market for them. but seems they only offer a very limited application.

 

I would use MDF personally. It's pretty darn sturdy when you have 1/2" and if you covered it with vinyl it would be pretty water resistant as well. Only downside I can see is it would be heavy. I work with 3/4" mdf for speaker boxes and it's solid stuff. I don't know how stiff the 1/4" mdf is but if you go to home depot you can easily find a damaged 4x8' for cheap. It's easy to cut and work with as well. I think I got my last sheet of 3/4" for 15 bucks. Gives you enough material to mess around with it a bit.

 

Krypto I used 1/4 MDF on the panels I made for my truck and it is way too heavy...
the hinge bushings are getting worn out... going to have to remake them again using 1/8" hardboard as the base.

1/2" MDF would not clear the gap between the upper corner of the door panel and the edge of the dash. The 1/4" MDF is tight already.

IK were talking about the OP's 1gen verses my 3gen but the clearances are similar at that pt.
My cousin had an 83 and the stock panels were pretty tight there.

 

Yeah I was thinking about that after I posted. MDF is solid but it is heeavvy. Well there's one other material you could use but it takes some time. Fiberglass. Takes a while to form up but it's not too bad once you get used to working with it.

 

Oh man ocdropzone, that looks excellent. Oh great, another mod just got added to my list! This one might take awhile, diamond plate isn't cheap up here.

 

[QUOTE=ocdropzone;51823261]This took me about 20 minutes:


That looks AWESOME!!! I'm thinkin I might do something like this too!!
Nice work ocdropzone!!!!

 

I have those one, still looking for this model of handle!
Anyone ........

 

those are the lower end handles. my 79 had the "fancy cab option" the better door handles,carpet and guages. the sr5 handles are easier to use and more comfortable too. but it's not my truck!

 

Update on that FRP company. They mainly deal in large quantities and charge a $40 broken pallet fee. For them to get it to me in ND would have cost $200. Altogether would have been almost $300 for a 4x10 sheet.

 

I forwarded your request to TrekkerPaul--he has a huge collection of door handles..