On to the most challenging part - the door cards. Those of a nervous disposition might want to change the channel at this point...
Cut the top off the red FE door card with a sawzall
Cleaned up the edges with the dremel to leave just the bit I wanted
I did the opposite with the black door cards from the donor interior, just keeping the top piece.
I did some experimenting with different types of adhesive using a scrap bit of the door card ABS plastic. I clamped up three pieces overnight and then measured the force required to break them the following morning
The 2-component Plastic Doctor at the top is by far the strongest - the plastic itself broke before the glue gave way, however with a 2-3 minute max working time it was useless for the task at hand. The airfix glue (remember that?) at the bottom was the weakest of the three but still very strong and also the easiest to work with, since it didn't require mixing and had a 10 minute working time. Given the surface area I was working with I deemed its strength to be acceptable so off I went.
Swapped over the door catch, speaker grille, and vents, and one door card is complete. It took three full days work from the first cut to this picture, for each of the four panels, including cleaning and treating the leather.
Fitted to the car
Same process with the tunnel trims
