yellowXB Posted July 28, 2013 Author Report Posted July 28, 2013 I started on the door panel builds now. It seems like it took me forever and a day (it really did, 2 years) to decide how I wanted the doors to look. Since my car is based around old school stuff, I wanted something simple but yet different with my XB. For some reason, I have "HATED" the factory stock door panels from day one. I've not seen any elaborate how tos on the doors that were for an XB, it seems like most XB'ers leave the door panels stock and just change the arm rest cover material. I started by cutting out the area that I did not like on the door that i wanted to modify. The next step was to cut out a back piece of 1/4" plywood for a back. I did this because the door panel is now flimsy at this point and I needed it to be one stable piece again. This will be remove later. I have attached small screws through the front of the plastic. The next step was to test fit the door in the car to make sure it fit properly. The next photo shows the outer shell of the 3/4" wood that was cut. I put screws in from the backside of the 1/4" plywood back to secure the front shell design to the door. The test fit was perfect in the car. After i got my design and tested it in the car, i started the fleecing, stretching it tight. The panel was resin to the door. being plastic, it will pop off. I had to do it this way because I had secured the pods and the master power switch in a certain location. To sand it, I took the screws out from the backside of the door panel, holding the front piece I made. Took a claw hammer and gently pulled on it to loosen the front piece form the plastic. It popped right off with little effort. Then I began to sand down the rough areas. I had some felt left over and wanted to see a general idea of the finished product so I wrapped the door panel.. BTW, never use felt everything sticks to it.. I believe I may go with tweed on the doors. BTW, the back piece of 1/4" plywood, it was temporary and was removed after the front piece was created. To secure the front fiberglass piece to the door, I used about 25 small self tapping screws, screwing in from the back side of the door..
yellowXB Posted September 16, 2013 Author Report Posted September 16, 2013 Part 2 of this build can be found here.... http://www.stevemeadedesigns.com/board/topic/173983-2005-scion-xb-1st-gen-wall-build-b-pillar-build-2/
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