1970 VW Karmann Ghia - Door Panel Installation:

Video Transcript:

Intro 0:00 Follow along, as we close the door on this door panel installation. Door sill plate installation 0:10 Yes, we are calling this a door panel installation video 0:14 but we have some other things to do as well so we'll start this video where we finish the carpet video. 0:19 By installing door sill plates which finish out the exposed edge of the carpet pieces on the door sills. 0:25 And the driver side sill also covers the main wiring harness. 0:29 Once the sills are set in place, they are screwed in and we can get to working on our doors. 0:35 While we're doing all this though if you would do us a favor and click the like and subscribe buttons. Door check rod installation 0:40 With the sales in place, we can get started by replacing the worn door check rods 0:44 as we're tired of using a pair of vice grips to hold the doors open. 0:48 There is a small tension clip at the top of the pin which can be popped up with a small flat blade screwdriver or knife. 0:54 Or you could just tap the pin down and free of the clip the clips. 0:58 The clips are small and very easy to lose so be careful when popping them off and putting them back on. 1:05 Next, the check rod pin is removed. 1:08 Inside the door, we remove one of the two pins inside the door that holds the rollers in place around the check rod. 1:15 Tapping a punch that is slightly smaller than the pin works great to remove the pin 1:19 and most the time it catches the pin when it comes loose. 1:23 We got lucky on this one as it just caught the edge of the clip. 1:27 The pin is removed along with the plastic roller. 1:30 The old check rod can now be removed and we compare is to the new piece. 1:36 The rubber on the check rod squeezes between the rollers which hold tension on the door to hold it open, 1:41 and the check rod also prevents the door from opening too far. 1:44 The new check rod is installed through the door, with a smoother end sticking towards the door jamb. 1:50 The original plastic roller set in place, 1:54 and the pin is pushed down and back in place to hold it. 1:57 Now the tricky part is getting the tension clip back on. 2:01 The edges of the clip are spread out around the same punch that we used to remove the pin. 2:05 The clip is set in place around the pin and the punch is pulled away from it. 2:10 Then we use the punch to push the clip into place to secure it on the pin. 2:15 It isn't easy to show you inside the door while this is happening, especially with my hands in the way. 2:20 But, we can take a picture once my hands are out 2:22 and you can see the clip in place along with the new check rod. 2:27 Next, we set the check rod in place at the hinge on the door jamb, 2:31 push the pin into place, and reinstall the clip at the top. 2:37 We use a small socket and driver to get it set in place and then push it down with a flat blade screwdriver. 2:44 The same steps are used on the opposite side check rod. 2:47 Our punch did a much better job of catching the clip inside the door. 2:51 We finished with another picture to show that using a punch to install the clip inside the door again wasn't just a fluke. Rear quarter panel installation 2:59 Now, we can get to actually installing the door panels and we're actually going to start at the rear quarter panels. 3:05 After making sure we have a clear path between the carpet and the body for the panel, 3:11 we install the door panel clips into the panel. 3:14 I find a pair of linesman pliers works best, 3:16 and while holding the body portion of the clip I slide the loop portion of the clip into the panel. 3:24 Once the open end can be slid onto the panel, it's pulled towards the edge. 3:28 I normally point all the clips towards the edge of the panel. 3:32 Setting the panel against the body helps as a reference to align the clips once they've all been installed. 3:39 The quarter panel can be slid into place, the clips are further aligned as needed, and the panel is snapped into the body. 3:47 The same process is used on the opposite side panel and then we can get to work on the front door panels. Front door panel installation 3:54 We start by removing the armrest brackets from the old panels. 3:58 With our new panel in hand, we note the various pre-perforated holes in the panel. 4:03 Including; six different arm rest positions, 4:06 holes for early model window cranks and or release levers, 4:10 and of course the two punched holes for the door release lever and window crank. 4:15 They have some cloth material backing covering the holes so we cut it away. 4:20 Using the old panel as a guide, we set the old and new panels together and poke through the 4:25 old armrest holes into the new panel so we know which of the armrest holes we need to remove 4:32 The poked out pieces are pulled from the new door panel. 4:35 A new screwdriver is poked through the door panel material so we can install the armrest. 4:40 After we install all the door panel clips. 4:43 A new armrest is pushed through the door panel, 4:46 and the original brackets are installed under the armrest to hold it in place. 4:51 Now at the car, we install door panel clip seals at all the holes around the door panel opening. 4:58 Here we note that if you plan on driving in inclement weather, 5:01 washing it with a hose, 5:03 and generally don't mind water running through your door, 5:06 you want to install a plastic vapor barrier. 5:09 Like we did on our Super Beetle restoration. 5:12 Since this car was actually missing some seals, 5:15 and the old door panels don't have any water damage, 5:18 we're going to guess this car is fairly well cared for 5:21 and won't be seeing much water so we're not going to install them. 5:26 We set the door panel up to the door and checked the alignment of the door panel clips. 5:31 Then, we set the armrest bracket above the hook on the door and slide the door panel into place. 5:37 We press the clips into the door, adjusting them as needed, 5:42 and once they're all pushed into place, we install the window crank, 5:48 door release trim plate, and finish by snapping in the door finger cover plate. 5:54 The opposite side door panel installed in the same manner. 5:58 We finish off this video by reinstalling the retrofitted late model dash back into place. 6:03 In our next video we'll get the rear seat upholstery installed. 6:07 Until then, thanks for watching and let us know if you have any questions in the comments below. 4:09 NOW PLAYING 元気ロケッツ - Star Line HD Z400N 851K views