How To Build Custom Door Panels - Sintra/Expanded PVC Fabrication

36 hours worth of work later we have a door panel...

Welcome to (does stuff garage) - Today I'm gonna show you how I built custom door panels on our 1963 Buick Riviera LS swapped project car. I started with a few sheets of 1/4 and 3/8 inch Sintra boards which is a brand name for expanded PVC sheeting. I chose this material because all the tools you use for wood can be reused and its waterproof. It's also way less mess than fiberglass. Once I got them cut into manageable pieces - I laid out some cardboard and made a pattern of what the old door panel probably looked like. Once I traced and cut two copies of that out of the Cintra I test fit everything back on the car and did some trimming/sanding to get everything to fit.

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Then comes the fun part - my center recessed panel is inspired by 1966 Ford Mustang door panel. Not only is it a pretty attractive design from the factory, it looks pretty nice on other cars too! You can even order the outer chrome trim bezels from suppliers like CJ Pony and use those to make pattern from.

To make the center panel more interesting I added some speed lines with a router and a scrap board moved across the panel matching the back angle of the center panel. Be sure to make you grooves a little bigger then you think you need because once you vinyl/upholstery it your lines will not look as intense. I also finished up the edges of the panel with some 45 degree angles and rounded corners.

The best glue for Sintra is Christy's Red Hot PVC Blue Glue - it's my favorite glue for this type of project. Epoxy and CA glue/accelerator also works well depending on what you have access too. Be sure to install your christmas trees/clips/hurricane nuts in between the panel before you fasten them together. Stay tuned to the next DIY videos for adding sound deadener and building arm rests!

#projectcar #fabrication