Strengthening Door Panel
Thread Starter
Instructor
Joined: Jan 2009
Posts: 155
Likes: 0
From: Mesa AZ
Strengthening Door Panel
Hey guys, looking for ideas from the restoration/body specialists out there. I’d like to increase the structural integrity of the door panels on my C5 convertible. The vinyl covering is in excellent shape but the panel itself flexes way too much, resulting in various squeaks and rattles (yes we all know about the plastic interiors). I have no experience with body part repairs, but I do have a couple of thoughts. First is to strengthen the panel by applying fiberglass/resin to the interior. The other thought would be to use spray insulation foam and then trim to fit the inner spaces of the door. Am I off base with my thinking or is there something obvious I’m missing.
Last edited by 2KROADSTER; Dec 13, 2009 at 05:29 PM.
Safety Car
Joined: Mar 2007
Posts: 3,518
Likes: 37
Just do sound insulation for the door in the usual way. It makes the door feel much more solid and there are no noises or rattles coming from it. (And then they are soundproofed too.)
Take the door panel off.
With the window up reach in and put dynamat (Or like product on the outside skin of the door, cover as much as you can.
Then cover the front of the door just under the panel with dynamat. Be sure to keep the dynamat away from the moving parts to prevent any binding, otherwise try to get as full of coverage as you can.
THEN cover that dynamat with dynaliner (Or similar product, dynaliner is 1/4 inck closed cell foam with adhesive back.) This layer keeps any rattles from happening and helps the whole thing feel nice and solid.
Replace your door panel.
Doing that should give you the feel you are looking for.
Take the door panel off.
With the window up reach in and put dynamat (Or like product on the outside skin of the door, cover as much as you can.
Then cover the front of the door just under the panel with dynamat. Be sure to keep the dynamat away from the moving parts to prevent any binding, otherwise try to get as full of coverage as you can.
THEN cover that dynamat with dynaliner (Or similar product, dynaliner is 1/4 inck closed cell foam with adhesive back.) This layer keeps any rattles from happening and helps the whole thing feel nice and solid.
Replace your door panel.
Doing that should give you the feel you are looking for.
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If you do something to the panels, please document what you did and share with us - would be interesting to see and hear how it works out.
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Le Mans Master
Joined: Aug 1999
Posts: 5,515
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From: Silicon Valley and Yosemite, CA
I will have to say my door panels are rock solid/zero vibration. When I pulled the Blose system and went aftermarket, I reglued the foam in the upper door panels with 3M Contact cement. 6+ years later it is still holding.
Then I tightened the speaker cover by pinching the tabs tighter and covering the tabs with silicone, and then took 1/8 weatherstripping and put it in between each of the pins around the outer edge.
The panels are dead silent, absolutely no vibration for over 6 years
Then I tightened the speaker cover by pinching the tabs tighter and covering the tabs with silicone, and then took 1/8 weatherstripping and put it in between each of the pins around the outer edge.
The panels are dead silent, absolutely no vibration for over 6 years
Thread Starter
Instructor
Joined: Jan 2009
Posts: 155
Likes: 0
From: Mesa AZ
Originally Posted by DUB
If the area that allows you to push it in 1/2" or so is open behind the door panel. You could try by cutting a piece of rigid/semi-rigid stryofoam and installing it to the backside of the soor panel...as long as it does not effeect you removing/installing the door panel. Just a thought. Also...if you feel like it. You could take a plastic bag and shoot expandable foam into it and quickly install the door panel and allow the foam to fill in the void. The plastic bag will make it so you do not make a mess...and may require adding more foam to it...in case you did not get enough in the bag the first time. The plastic bag will form to the backside of the door panel along with the door inner structure...and will be able to be removed and re-installed due to its shape. Just another thought.
"DUB"
I'll let you guys know how my little project turns out. Stay tuned
Le Mans Master
Joined: May 2006
Posts: 6,774
Likes: 363
From: Midland TX
If you are getting rattles/squeaks in the doors and the door skin and hinge attachments themselves are in good shape, there are only 3 places this noise could be coming from:
(1) the window hardware inside the door (tighten all suspect elements)
(2) the door panel itself (not usually the source, but can be padded with Ensolite)
(3) the surfaces between the door panel and structural elements rubbing (VERY likely if nylon clips are not aligned properly or not fully engaged - adding Ensolite to the back side of the panel will also help avoid the vinyl cover from making direct contact with the metal structure)
Just adding fiberglass or "weight" to the panel will not help most likely and may actually make things worse!
My doors have been dead solid since I modified them nearly 3 years ago. To see what I did, you can check out this thread http://forums.corvetteforum.com/c5-g...g-article.html and look at the first 7 pics.
Strong or Heavy door panels are not the answer - Ideally they would be lightweight and soft "spongy" material to eliminate noise - "soft/spongy" things do not "squeak or rattle"
(1) the window hardware inside the door (tighten all suspect elements)
(2) the door panel itself (not usually the source, but can be padded with Ensolite)
(3) the surfaces between the door panel and structural elements rubbing (VERY likely if nylon clips are not aligned properly or not fully engaged - adding Ensolite to the back side of the panel will also help avoid the vinyl cover from making direct contact with the metal structure)
Just adding fiberglass or "weight" to the panel will not help most likely and may actually make things worse!
My doors have been dead solid since I modified them nearly 3 years ago. To see what I did, you can check out this thread http://forums.corvetteforum.com/c5-g...g-article.html and look at the first 7 pics.
Strong or Heavy door panels are not the answer - Ideally they would be lightweight and soft "spongy" material to eliminate noise - "soft/spongy" things do not "squeak or rattle"
Last edited by Choreo; Dec 16, 2009 at 01:53 AM.
Thread Starter
Instructor
Joined: Jan 2009
Posts: 155
Likes: 0
From: Mesa AZ
If you are getting rattles/squeaks in the doors and the door skin and hinge attachments themselves are in good shape, there are only 3 places this noise could be coming from:
(1) the window hardware inside the door (tighten all suspect elements)
(2) the door panel itself (not usually the source, but can be padded with Ensolite)
(3) the surfaces between the door panel and structural elements rubbing (VERY likely if nylon clips are not aligned properly or not fully engaged - adding Ensolite to the back side of the panel will also help avoid the vinyl cover from making direct contact with the metal structure)
Just adding fiberglass or "weight" to the panel will not help most likely and may actually make things worse!
My doors have been dead solid since I modified them nearly 3 years ago. To see what I did, you can check out this thread http://forums.corvetteforum.com/c5-g...g-article.html and look at the first 7 pics.
Strong or Heavy door panels are not the answer - Ideally they would be lightweight and soft "spongy" material to eliminate noise - "soft/spongy" things do not "squeak or rattle"
(1) the window hardware inside the door (tighten all suspect elements)
(2) the door panel itself (not usually the source, but can be padded with Ensolite)
(3) the surfaces between the door panel and structural elements rubbing (VERY likely if nylon clips are not aligned properly or not fully engaged - adding Ensolite to the back side of the panel will also help avoid the vinyl cover from making direct contact with the metal structure)
Just adding fiberglass or "weight" to the panel will not help most likely and may actually make things worse!
My doors have been dead solid since I modified them nearly 3 years ago. To see what I did, you can check out this thread http://forums.corvetteforum.com/c5-g...g-article.html and look at the first 7 pics.
Strong or Heavy door panels are not the answer - Ideally they would be lightweight and soft "spongy" material to eliminate noise - "soft/spongy" things do not "squeak or rattle"
Le Mans Master
Joined: May 2006
Posts: 6,774
Likes: 363
From: Midland TX
Yes, as I am sure you probably know, the Dynamat will not get rid of rattles and squeaks (unless two adjoining panels that were not secure were covered by a single piece). If it is a "rattle" then something is probably loose. If it is a squeak, then it is most likely the trim panel rubbing against something or it is not secure. You might try driving around with the trim off to see if it still squeaks - if so, you have narrowed the problem down.
