Just thought I'd post up kudoos to WILCOX for supplying a quality deluxe door panel (Corvette America mfr). EXCELLENT fit and finish! They were a glove fit! Sure, I sweated a little carving out holes for the cranks on the window and vent as well as the door pulls and lock area. I made up my mind that b/4 I put the panels on I would finally address the "loose change" sounds inside the door.

Sure enough, the release lever your ball screws onto was totally worn out (flopping around) as well as the rag sleeve covering the long rod. Vapor barrier was trashed as well. Replaced with new and took the time to spray down using brake cleaner all the inner mechanisms of the door. After spraying all of this down I liberally sprayed lithium grease to all moving parts.

The driver's door had 3 rivets that had come loose. I took JohnZ's cue of using a protruded weld nut 1/4x20 by 3/4". This is a threaded stud with a flat head mirroring those rivets. The repair tightened up the door and aided my realignment of her.

Pass door vertical vent window weatherstrip was shot. Was able to remove just that vertical portion with a new one and replaced the felt runner for the exposed portion of the window channel.

With new round foam/plastic cushions all in the right places on the door and the new plastic vapor barrier strip caulked to the door, I finally installed the new deluxe panels, making use of a dead blow hammer to "encourage" the cranks and door lock handle in place.

This ain't a one man job. I was glad to have my neighbor Jim Minton provide a 2nd set of eyes and hands to help with this install.

The doors shut with a "chunk". The glass glides up and down the channel effortlessly. Sitting in the car and pulling the inside release ball to open the door, she pops right away from the jam slightly. Before my wife had to throw her shoulder into the door to "aid" in opening. A lot of times the ball handle would stick in the release position.

All of this took time. Sure didn't make much an hour paying myself on this project but it indeed was gratifying to see the finish product pay off as well as it did. Time well spent. The doors are solid and I've got to tell ya' my wife sat in the pass seat and closed the door and just smiled. When she tried the windows and then opened the door to get out, she just smiled the more!

I encourage all of you who experience this "loose change" sound in your doors to take the time to address the inner workings of these doors. The hardware on my '5 is 45 years old and it showed it.

Pics on all the above follow.

Jim
In God We Trust!

 

Here are a few more pics.

Jim
In God We Trust!

 

Looks great Jim! I sure wish CA had done a better job in closing the gap at the vent window. It bugs me to see door guts!

Well, if your cranks lined up and the armrest screws went right in --that definitely is an improvement.

 

Thanks Mike. I hear ya' about that gap. I made note from my original panels of the fit in that area and it IS exposed on my originals as well. I had hoped the new panels would have closed that gap up (thinking the originals warped over time to create that gap). Maybe ignorance is bliss. I am happy with the overall results on this install.

Not certain if Al Knoch's panels would have fit any better in that area. Perhaps others here could post up their pics of their success story in that area.

I did prep the bolt holes for the door pulls and the arm rest holes. I used plastic inserts for the door pulls and tapped the bolt holes for the armrests. There was a recent thread where someone had "stood on their head" to get the bolts in the holes. I ended up taking an awl and noted the angle and after a few attempts was able to mirror that angle with the bolts. WALLLAH! One does have to approach this job with patience. It does help to have a 2nd set of hands

Jim
In God We Trust!

 

The originals on my 65 coupe fit tight against the rubber W/S around the vent window. No gap at all.

Jim

 

Jim,

Can you post up pics of that.

Thanks!

Jim
In God We Trust!

 

Here ya go. Both panels seem to be "bent" a little for a tight fit by the vent window. Mine have never been removed from the car so that's the way it came from the factory.

 

Thanks Jim. I see what you mean. Apparently, that trim piece that goes up your A pillar might help keep your panel tighter to the vent window horizontal base. I've just never paid attention to that portion of the door on a coupe. Does look cleaner.

Jim
In God We Trust!