YODAONE

Have removed the front passenger door interior panel to seal the door panel pocket...

The lower door panel consists of a particle board type structure overlaid with vinyl.

The assembly appears to be manufactured with a blank of interior color vinyl sheet joined to the press board substructure under high pressure and heat..

Good quality vinyl and sub structure.

However, through decades of use, the press board flexes and develops stress cracks, particularly where fastened to the armrest and upper door panel.

Easy to remedy...

To fortify the stressed areas, remedy particle fissures/popping and decrease flexing, added two light coats of Varathane Wood Hardener to the particle board.

Important to avoid contact with vinyl and plastic parts, so using a 1" brush provides better control and application accuracy.

The particle board is bone dry, so it is best to apply two or three light coats to avoid soaking the wood like syrup on pancakes.

The Varathane noticeably stiffened the mounting areas and reconstituted those areas where wood fibres were exhibiting separation.


Some wood particle separation surrounding fastener head.

Slight cracking of particle board.

Beginning of wood fibre separation and cracking due to flexure over time


A more pronounced crack around plastic positioning pin.


Use wood hardener in well ventilated area.

YODAONE

Acquired spare passenger door panel as a yard pull because it had zero nicks, blemishes or abrasions...

While disassembled, observed the black plastic support which extends just below the opening of door panel pocket, exhibited cracks.

Have a spare on hand, so remove original - the pieces popped right off, scraped old green adhesive (brittle) and applied JB Plastic Bond Adhesive.


Image of work area behind door panel depicting replacement part clamped while epoxy is curing, and pieces of original support.