Fitment Problem with Reproduction Door Panel- C3

[Mark E.]

I want to share a fitment problem with reproduction Al Knoch 1970 door panels. Hopefully this will help you avoid similar issues by understanding what to look for when buying panels.

When installed, the upper rear corner of the panel will pop loose from its locating tab on the inner door (shown in the first photo), leaving a large gap between the glass and whiskers. Before the panel "pops" loose, the tab on the door is exerting a lot of strain on the panel to keep it in place.

Why? The door panel does not fit flush against the inner door steel as the original. Why? Interference between the fasteners for the door trim (second photo) and the inner door (see paint scratch next to screwdriver- 3rd photo). Why? A variety of improper fitting screws and washers attaching the panel trim (second photo) stick out causing interference.

The panel is attached with its two clips, but the front and rear attaching screws are not installed. I'm worried that using these screws to draw the panel to the door (there's about a 1/2" gap) may cause the vinyl to tear.

The fourth photo shows another rouge fastener used at the bottom of the panel which also causes the panel to stick out.

I called Al Knoch a few hours ago and left a message. I'll keep you posted.

[Patrick H.]

Re: Fitment Problem with Reproduction Door Panel- C3

I'd swap out/modify the fasteners and retainers that are there, and move on.

As Rich Mozzetta has shown us many times, it's a rare day when a reproduction part fits well and works as intended.

[Gary R.]

Re: Fitment Problem with Reproduction Door Panel- C3

I've heard the interior parts over the past 10 years are not like they once were. I don't get into changing our interiors but bought a complete new interior 30 years ago for my 69 and hope it fits. I can't believe it's been that long now. I still have some back cardboard 69 panels and also some of the plastic ones. I will watch this thread to see how you make out. About 10 years ago I bought a complete AK black carpet set for our 75 and when we opened it up to use it months later found there were a mixed batch of parts in it. The 80-20 loop was different as was the shade of black. I brought it back to Al that following year at Carlisle and he swapped it out no problem.

[Mark E.]

Re: Fitment Problem with Reproduction Door Panel- C3

Elliot Knoch (Al's son) called back. I showed him the photos, and he said he would send a proper, matched set of trim attaching hardware for me to install.

Stay tuned.

[Russ S.]

Re: Fitment Problem with Reproduction Door Panel- C3

Mark, Is the back side of that panel black plastic? I thought AKs panels were like the original cardboard.

[Mark E.]

Re: Fitment Problem with Reproduction Door Panel- C3

These are an ABS type material. I don't know if they also offer original style fiberboard, but I don't think so.

[Don L.]

Re: Fitment Problem with Reproduction Door Panel- C3

These are an ABS type material. I don't know if they also offer original style fiberboard, but I don't think so.

They do, or at least they did a couple years ago when I looked into it.

[David C.]

Re: Fitment Problem with Reproduction Door Panel- C3

Mark, whatever happened with your door panel fitment? How did you resolve it?

[Mark E.]

Re: Fitment Problem with Reproduction Door Panel- C3

I returned the repro panels to Al Knoch to see if they could get them to fit properly. Driver's side was marginal; the passenger's side would not fit at all. They "shaped" the plastic frames using old doors as jigs, and shipped them back. The passenger's side still did not fit.

I called them to advise of the continued fitment problem; they questioned if I was installing them properly or if I had an out of spec door. So I drove to Carr's Corvettes to have them check. They could not get the panel to fit my door or another door at the shop. They trial fitted another panel they had on my door with no problems. (Carr's are good guys- they checked this while I watched and didn't want to charge me. I personally gave the mechanic a few bucks anyway.)

I gave up on the ABS panels, but I still had my original panels and Al Knoch agreed to recover them. So I shipped both the original set and their repro set back.

After a few weeks, I received my original panels recovered by them... The right one didn't fit because they used a hodge-podge set of fasteners for the trim, which prevented the panel from properly seating against the door. So I shipped the original set back for them to rework the fasteners.

This last round of rework was satisfactory.

Bottom line: Their ABS backed panels have fitment problems. Recovering your original covers may be the best option: they fit well and the date code on the back is preserved. Even if the fiberboard is damaged, they use a pressure mold process to repair it as needed. The drawback is this takes a few weeks and may require a round or two of rework.

[David C.]

Re: Fitment Problem with Reproduction Door Panel- C3

Thank you Mark, appreciate your explanation.
When you say recover, is that with some kind of vinyl skin which goes over the original panel? Or some other process?

[Bob W.]

Re: Fitment Problem with Reproduction Door Panel- C3

Mark, I was thinking about having Al do the same for me. I have heard about the problems with the abs backing. What was the cost and did he install new whiskers?

Thanks Bob

[Mark E.]

Re: Fitment Problem with Reproduction Door Panel- C3

Thank you Mark, appreciate your explanation.
When you say recover, is that with some kind of vinyl skin which goes over the original panel? Or some other process?

David,

Using original door panels, AK removes the skin and underlying foam, repairs the fiberboard as needed, then uses a ther****rming (or maybe vacuum forming; don't remember) process to add new foam and skin. The process is similar to how the panel was originally produced.

[Mark E.]

Re: Fitment Problem with Reproduction Door Panel- C3

Mark, I was thinking about having Al do the same for me. I have heard about the problems with the abs backing. What was the cost and did he install new whiskers?

Thanks Bob

Bob,

I don't remember specific pricing; it's been awhile. They do offer show discounts at NCRS and other events they attend. I believe having your existing panels redone is the least expensive option.
B

[Bob W.]

Re: Fitment Problem with Reproduction Door Panel- C3

Mark, Thanks for the reply Al is at the spring/ fall & corvette Carlisle so I will talk to him about this then.

Thanks again Bob

[Sal C.]

Re: Fitment Problem with Reproduction Door Panel- C3

Only one example of why premium ORIGINAL parts command premium $$$.