Peugeot 206 Door Builds

[Steve.]

Having bought;

5kg pack General Purpose Resin
Bucket(s) 550ml each
Resin Brush 12mm (0.5") Box of 12
2kg Roll CSM 600gm
Easy Sand Body Filler 1.5kg pack
Surgical Latex Gloves 50 pair box
Calibrated Mixing Cup 10 pack
Syringe 50ml
Mixing Sticks 100 pack
Acetone 2.5 litre

Its time to start my door pods! Is my first time with fiberglass so it’s a big thanks to Amit for his tutorial’s.
Unfortunately completely forgot fibre filler so off to Halfords I trot. (I will be writing this as I go so I don’t have a big write up at the end )

Tools used;
Jigsaw
Hacksaw
Stanley knife (with 10’s of blades)
Chalk (to mark out lines to cut)
Angle grinder with a sanding disc
Drill
Sand paper (and block)
File
Drill (with sanding disc)



I don’t have a router so its jigsaw all the way.
I cut two rings, a thicker one and a thinner one to give the flush mounted speaker baffle. It was a bit more work but the main thing is the inner rim came out pretty good after a quick sand.




The door fabric was removed by drilling out the fixing points so it doesn’t get in the way.

The next stage was to slowly cut more and more of the card away as I needed and sat in the car (with the aid of Claire) to work out what position will give me the biggest mounting depth with least interference in the footwell. Eventually bring the speaker ring more into the door solved my problem and here started the aiming.
Sat there with bluetack, a ruler and pieces of offcut plastic and eventually got the ring to stay in just the right place.






Carefully moving it to the garage where I glue gunned some battons to the card to hold the ring in place








Next I chalked out a line that I thought matched the flow of the door well





Then cut with a stanley knife carefully (I must have been through about 10 blades with all this cutting, they don’t like corners much )





The next step was to sand, drill and score the card with a knife to give it a nice key
(Note dads message, along the lines of ‘Nothing, I mean nothing is to be left on here..blah blah blah blah – Yea right! )





Both cards done, to set the aiming I carefully copied the first card, in the view of putting it in the car and just shortening or lengthening the battons to aim correctly. On putting it in the car it was pretty much spot on! (Thank god something goes right)





The next stage was to round off some of the edges with some fibre filler. This is so that when I stretch the fabric over it I won’t get an edge. I realize I could use filler over it later to smooth it out, but it seemed easier and more logical to round off the edge first.

Obviously sanded and then drilled and scored again for the fg.

[Steve.]

Now I’m at the stage to re-attach the fabric for the doors, so as I progress with the pods I can offer them up to check the fitment.
I used a glue gun to re-attach the trim.






As you can see before I put the trim back in a small section was cut out to allow the speaker ring to sit nicely (In the end I actually cut more than this)





Next I stole one of mums tee-shirt’s to stretch over the pod. (I removed the staples in the baffle etc. so not to get in the way)







Next is the first layer of matting. Shaping up nicely don’t you think?
Got a few layers + on the front.





Then I thickened it up a bit by adding some more layers on the inner side





Next I took to it with the angle grinder with a sanding disc, Smoothed out high spots, and blended the joins as well as I could.

[Steve.]

I had to cut out a lot of fiberglass where the pod will join the door and basically took it back to stock with the grinder and sanding pad. Offering it up to the door I’m getting pretty close.







Unfortunately I noticed that the curves on one pod aren’t exactly the same as the other (from when I originally stretched the tee-shirt) so out comes the grinder again. Followed with fiber filler to get the shape back.







Next was first layer of filler to smooth it out.





I thought I better get some sort of top in, if only roughly in fiber filler





Another layer of filler and sanding.





Getting there…

[Steve.]

But wait, after a quick test fit it seems Stevens been a prize idiot and as the card had no structure when I stretched the tee-shirt over it, it warped

So out comes the jigsaw





Clamped and fiberglassed then filled on top







Done at last!





So now for the trimming in some suede effect (apparently) vinyl using some contact adhesive. After the nice chap at the upholsters offered me alacantara for under £50 a meter I still couldn’t afford it. He gave me a good long talk about how to do it all anyway.





Next tidying up the edges with some superglue and a knife





The only place I got wrinkles is on the underside corner, due to the lip which I cant say I’m that worried about as no one will ever see it.





Next I got out the duck tape to hold the card together (the most daunting bit!), then fiberglassing it tight together.

[Steve.]

Success!















Bit of expanding foam to give it some structure





Now fitting them wasn’t as easy as I’d hoped, they had still flexed slightly and a bit fatter due to the vinyl so the OEM clips didn’t hold, I tried all sorts, tried superglueing the clip on the outside of the card (wasn’t strong enough!). Then fiberglassing the clip on the outside, again didn’t work. In the end as I was going to sleep (best place to problem solve don’t you think!) I thought of using bolts.

So bolt in the card then reaching round and doing up the nut through the speaker hole.

I also touched up some areas with a bit of filler and paint, a good colour match (due to A-level art) as there was a slight gap.

[Steve.]

Done!














Now I was going to Fg the tweeters but frankly had enough as I’m off on a camping holiday with the rents on Wednesday! So was thinking about it and the a-pillar plastic is pretty flat where the tweets would go.....





With a bit of cutting and filing they actually came out really nicely flush mounted.

[SAB]

The end result is very nice however you have done the build the hardest way ever.
You should never have cut the bottom section of your door off there was no need ( you gave yourself a lot more work). The build should have beed built on top and flushed into the original door card.

And i do agree that you should cover or smooth the orgional speaker mounts.

On the whole a good job though, well done.

[Steve.]

Originally Posted by SAB

The end result is very nice however you have done the build the hardest way ever.
You should never have cut the bottom section of your door off there was no need ( you gave yourself a lot more work). The build should have beed built on top and flushed into the original door card.

And i do agree that you should cover or smooth the orgional speaker mounts.

On the whole a good job though, well done.

Thought about this alot, but then I only wanted to trim the lower section, I definately didn't want to trim the whole door (or paint it!) So this seemed like the obvious way to do it, so I could tuck the vinyl and then join it to give it a nice edge.

Originally Posted by Jim

wow, fantastic job, some amazing handywork there, was this your first time using fibreglass?

Yes mate virgin

[Steve.]

Oh and about the OE speaker grill, again thought about this alot. In the end there wasn't any natural lines I could work with to trim it. It would look very stupid just on its own trimmed and as above didn't want to do the whole door, I think it's an area of interest and it will more than likely stay.

[RickyLee53]

Very nice work.
Did the contact adhesive not start to soak though the fabric. It did with mine?
Mums got a 206 it would be nice in alcantara (sp) to match the seats glove box etc.

[Steve.]

No had no problems with it as its vinyl, probably would have on a material though. I did have the aid of my mother for the trimming, as she basically held it up off the build as I worked round it smoothing it.

I have to say trimming was harder than I thought, easier second time but I still shouted at mum

The alacantara would have been lovely. He showed it to me and as it was offcuts was under £50 a meter, but still really out of my price range

[Madmax]

www.woolies-trim.co.uk = £25 a metre for suede type material.

Looks damn good though

[Amit]

Top work dude.

Amit