C2 Door Panels

[Dave K.]

Now that the carpet installation is complete on my 66 roadster, I moved on to the door panels. My original door panels had cut vinyl in the areas that made repair difficult and the metal trim was damaged, therefore, I purchased new repro panels from Al Knoch. I purchased the deluxe option that included all of the metal trim preinstalled.

Needless to say, the fit of the new panels leaves a lot to be desired. The alignment of the window, vent window and lock mechanism shafts in the door panel molded cutouts is poor. The fastener clip cutouts (on the back of the panels) required additional t******* to bring the clips closer to the edge of the panel.

I’m using the lock mechanism shaft as a reference as it appears that the lock shaft must be centered in the panel recessed opening (for the lock knob), otherwise, the lock knob won’t go on to the shaft. There is very little clearance between the lock knob and the panel side in the recessed opening.

Has anybody found a better way to set the panel alignment and to install repro panels?

Regards,
Dave Kitch
33108

[Joe R.]

Re: C2 Door Panels

Dave,

Let's talk door panels and poor fit!

I just installed a set of NOS door panels dated 1966 on my 66 Roadster and they were no fun to install.

The door panels were perfect but the knobs on the door needed adjusting. The lock was especially hard to adjust.

But that's why GM made them adjustable.

I would suggest you consult a local upholstery specialist or some NCRS member (with upholstery experience) that can coach you thru the installation.

Door panels don't just fall on the door frame with the holes aligned perfectly. You have to work at it!

Regards,

JR

[Ed D.]

Re: C2 Door Panels

Speaking of Al Knoch ... I just installed his carpet in my 65 and was very disappointed. The front was too long and no way to trim the driver side because of the finished trim edge on the back end and the gas pedal cut out in the front. I installed it for now but will recarpet it again later.

[Dave K.]

Re: C2 Door Panels

J,

I'm of the opinion that only the lock mechanism and wirg vent mechanism shafts cane be adjusted and than -- not much. Did you do your panels yourself? If so, could you elaborate a little on the adjustments available? These is nothing in the AIM or the service manual about adjusting the mechanism assemblies.

Regards,
Dave Kitch
33108

[Joe R.]

Re: C2 Door Panels

Dave,

One of the joys of being poor is learning to do it yourself. Only the engine machine work is farmed out here. Everything else is done in house including the painting.

Each of the items that go thru the door panel openings, lock, door pull and window crank are adjustable to fit your door. They all are held in by large 1/4" philips head screws on thin steel plates. These plates can be drilled, elongated or ground.

Try loosening each philips head screw and try to work the plate (shaft) into position before drilling or grinding. It may do the trick or you may have to make the hole for the screw a little bit larger.

Make sure to check each function after centering the shaft in the door panel hole. It takes patience and a little time but you can install the door panels by carefully fitting them to each door.

Hope this helps you with your project. You may feel free to contact me via e-mail.

Regards,

JR

[Timothy B.]

Re: C2 Door Panels

Dave,

I also had trouble with Al Knoch panels initially, but discovered that they had not installed the upper metal correctly. The problem is with the repro upper metal pieces, and the result is that the cardboard of the door panel doesn't line up right with everything else. If you search the archives from last year, you should find a couple of strings discussing the problems and my experiences. If you keep your original panels, you can send them into Al and have them build new panels around them and they WILL fit much better. If you can't find the threads I mentioned, send me an email and I will track them down.

[Dave K.]

Re: C2 Door Panels

Tim,

I found those threads in the archives. My biggest problem apears to be the lock mechanism shaft. I purchased new repros from Al Knoch several years ago and am just getting around to installing them. I can't get a good fit with the repros without a lot of jostling. I wonder if they'll do anything about it now. I need to call "Art" at Al Knoch. I'll talk to Al Knoch first before I try to readjust door hardware to fit the panels.

Regards,
Dave Kitch