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Thread: How To Re-Trim Door Cards (Astra mk3) - 56k No Chance

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    How To Re-Trim Door Cards (Astra mk3) - 56k No Chance

    It wouldn't let me add this into the member's guides area, so am putting it here for now This is by no means a "definitive guide" - purely just how I effectively did mine

    Time - One hour per door card for a total rookie.
    Cost - Not much... £10 for roll of material, coupla quid for some fabric glue.
    Tools Needed - See below


    Tools Required


    Staple gun is optional - just makes things a little easier later on. Also, I was pikey and used PVA glue (as both surfaces are porous). Ideally I'd have used proper fabric glue or something.


    Step One - Material

    I used leftover acoustic cloth ... hopefully going to try it sometime with alcantara. Make sure you've got enough material lmao don't want to feel silly later on.

    Step Two - Plastic Weldsl

    You'll see that the door card is mainly held on by plastic welds (as above). The only way to get rid of all of them efficiently is to drill them out.

    Be careful - Only take the head off, and do not drill deeper than the card. Tip - may be useful to get some large wire snips to cut any hanging bits of plastic off. May also need to sometimes drill sideways.
    Once the heads have been drilled off, it should look something like this -



    Step Three - Top Plastic Securing Triml


    Using a flat-blade screwdriver, tease the clips out on he top plastic trim bit out. Having also drilled the welds out, it should come out and look like this -



    Step Four - Take It All Apart
    Tease the card up, and drill any stubborn welds out if necessary. You'll be left with the main plastic trim and the door card!




    Step Five - Brute Force Required
    Grabbing a loose end or corner, rip up the old crappy material. If you can, lightly sand down the card below and pick off all of the foam.
    Insert old crappy material into dustbin. If you are environmentally aware, recycle material into a hat. If you aren't, make a bonfire with it.



    Step Six - Mincing
    Obtain food - in this case a Sainsbury's economy range currant bun.
    Insert foodstuffs into appropriate orifice - today we are using a mouth.



    Step Seven - Make It Fit
    Offer the new cool material up and try it for size. Then spend a while trimming it to make it fit. ]






    It's at this stage that you want a secure but temporary way of stopping the material from moving - I used some staples.


    Having done this, we can see here that we've got a bit too much material, so take it off and make it fit!


    The same applies to the back - make sure door handle, door lock pins etc are all clear.



    Step Eight - Fit It Back Together Again
    Right Gentlemen. If you know how to plastic weld, then go for it. For me - screws. I used a 3/4 x 8 screw .... Ideally I'd want a 1/2 x 8, but can't get them. By itself it's way too long and pierces the plastic on the other side, so I used about 3 washers per screw to bulk it out - don't be afraid to use more if need be! Stick yer grubby fingers on the other side to see if you can feel the screw piercing through. If you can - stop! If not, here's what happens if you don't use enough washers ..


    Finished screwing -




    Step Nine - *Ping*!! All done!
    Wahey!



    Then realised - bollocks! Missed a bit under the handle, oh well can't be seen lmao



    Any comments are welcome
    Rob

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    Who me or you?



    cheeky bugger

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    Great how to. I need to do that to the vectra.
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    Errm... no idea, never seen one.

    Take it off, and see if it's made the same way - with the plastic trim then the carpeted card back. If so, get that off and then should be the same ...

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    great thread easyrider.

    i didnt take the door card apart when i did mine, so the finish isnt very neat. Its good, but just rough in places.
    when i get some more material, Im going to try it again
    Astra Coupe 2.2 16v

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    I did this instead (old pics):





    Took about three months to sort out though.
    One dog goes one way and the other goes the other.
    And this guy's saying, "Whaddya want from me?"

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    Very nice job mate,... its actually not as complicated as I first imagined

    BTW, where did you get the blanking plate for the window winder shown here :



    Do you have electric windows ? If so, where have you put the buttons ?
    I'm planning on changing mine to elec at some point, but wondered how to cover up the holes for the winder.

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    Looks like a little speaker?
    The electric buttons go just under the handle. See the dip before the handle, that comes out and a two button panel goes in on the driver's side, and on the passenger side, you have a single, small button on the top of the door handle (another panel, which pops out).
    One dog goes one way and the other goes the other.
    And this guy's saying, "Whaddya want from me?"

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    Dom
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    I've copied this into the members area as well
    Doms online shop - www.picbits.co.uk/catalog,bulbs,cable,heatshrink etc
    Please don't ask for general advice by Private Messages - PMs are for PRIVATE MESSAGES. General advice should be asked on the Forums !

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    Quote Originally Posted by StationMiek
    Looks like a little speaker?
    The electric buttons go just under the handle. See the dip before the handle, that comes out and a two button panel goes in on the driver's side, and on the passenger side, you have a single, small button on the top of the door handle (another panel, which pops out).
    Ahaaa...

    I've seen the passenger one before, but never the drivers side. I presume if I get the plastic panel from a scrapper it should just fit straight into mine ?

    In the picture, where is the window winder ?

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    For electric or manual?
    You'll have to replace the wiring loom, and in some cases, connect a live to the loom you've just put in in the door. The electric mechanism is different in it has a small motor attached to it.
    One dog goes one way and the other goes the other.
    And this guy's saying, "Whaddya want from me?"

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    Quote Originally Posted by StationMiek
    For electric or manual?
    You'll have to replace the wiring loom, and in some cases, connect a live to the loom you've just put in in the door. The electric mechanism is different in it has a small motor attached to it.
    I know I'll have to change the door looms, regulators, and all that (time to redo my central locking mods ), I was just wondering will the plastic button panel from the drivers door in the donor car fit straight into my door... or will I need to change the door card ?

    Also, as for the window winder in that corsa... im just wondering where it is, by the look of the pic, the hole is blanked off, and I cant see a button for electrics anywhere.

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    No, it's not a speaker - it is a blanking plate.

    Previous owner (my dear old Grampa) had leccy windows installed as an aftermarket thing. The numpty's at Vaux didn't put the buttons in the conventional place in the handle on the driver's door card ... instead the whacked drilled holes through the centre console and whacked it in a box next to the handbrake!
    I've now moved it to my control panel, but am left with some nasty holes, so need a replacement console.

    PS: Cheers Dom
    Last edited by EasyRider; 07-06-2005 at 14:21.

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