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So my C4 was a good deal, but with all good deals come some work. I'm not the greatest DIY guy, but I do ok. I looked at the cost of new door panels, and that won't be happening any time soon, so I have a few questions. I have attached what I am working with.
The driver side panel will not come off. Someone made it rather permanent. Can the carpet be pulled and replaced? It looks pretty awful, and it peeling off in the front.
What can be done for the audio set up? That square hole is pretty ugly. I have a JL autio component to put in place of what is there, but I am unsure what to do to cover that hole. I see that the door sil comes really close to the opening, and there is'nt much room for material to go between the panel and the sil.
I would like to make it look at least complete if nothing else.
The door panels tend to get loose at the top may be why it was permanently attached. I have one of the original Bose speaker covers if that will help. I was missing one on my '88 when I got it. The speakers in my car had already been replaced with better ones. I used the one Bose cover that I had as a pattern to cut out a thin piece of plywood in the basic shape and with holes for the 4 screws. I then purchased 2 circular speaker grilles for just a few bucks that were slightly larger than the round speakers that were mounted. I then cut out round holes in the plywood to match the speakers and wrapped the plywood with some scrap black vinyl that I had. It seems like I used adhesive to stick the vinyl to the wood and used staples on the back to reinforce it. Anyway, this was my cheap fix and it actually looks pretty good and was a quick fix.
I have seen a thread on the forum that discussed redoing the carpet at the bottom. Keeping the edge from unraveling is likely the trickiest part. Probably also want to use relatively thin carpet and use heavy duty trim adhesive to hold it on. It is a shame the interior plastic and vinyl on the C4s does not hold up any better. Good luck and look forward to seeing some pics as you progress.
The door panel won't come off because you didn't follow the correct procedure to get it off.
The top hooks over the top of the metal door frame, so don't look there. You unscrew everything and then lift the panel UP to get it unhooked from the top of the door. Besides the screws along the bottom of the panel, there are two screws in the bottom of the place you grab to close the door. There are also several screws around the inside door handle, including one at the top in front of the map light that goes up at a 45° angle. As I recall, there's also one behind the inside door handle itself. There is also one screw on the back edge of the panel above the hatch release switch.
You need to take the inside door handle panel out before the door panel will come off. This is a major pain because of the windshield wiper switch, which is really big because it has the wiper delay and other stuff in it. You need to get the manual door lock "button" (the part that's got the red mark on it) off the door lock rod before removing the door handle panel.
I have taken mine off without removing the arm rest cushion, but it's difficult. The cushion is hard to get out because it has two (plastic!!!) hooks on it that go into notches in the door panel. You need to push the cushion toward the panel (outward -- to unhook it) while prying up on it to get it off.
no, thats not it. the door panel wont come off because the previous owner used screws in the panel, in various non factory places, and then covered them with a hard cloored resin