Inexpensive door panel reupholstery technique

Rejuvenate tired door panels with this inexpensive, but efficient technique

Upholstery Journal | October 2008

story and photos by Marshall Spiegel

  • This 1995 Audi 90 looks great, runs beautifully and is good on gas, so the owner decided to have the upholstery shop restore the interior, the car’s only real flaw.
  • After the owner explained his limited budget, upholsterer Max Chavez began by removing the dried foam and glue from the front door panel. Chavez uses a piece of scrap foam to clean the dried foam and glue from beneath the vinyl door panel section.
  • Chavez then carefully loosens the vinyl panel surrounding the door handle.
  • The final step in removing the dried foam and glue is blowing off the area using a pressurized air hose.
  • Masking tape is applied to protect the faux-wood trim on the door panel. When Chavez is satisfied that the area beneath the vinyl panel is clean, he prepares to begin the next step. Masking tape is applied to the border of the section to be covered.
  • Chavez then very carefully begins to bond the vinyl section back into position with spray-on upholsterers’ glue. Chavez continues applying the spray adhesive until the vinyl panel and the area beneath it are both saturated.
  • After the spray adhesive has been applied thoroughly, the protective masking tape is removed.
  • Now Chavez’s artistry begins as he works the edge of the vinyl panel into the existing depression in the door panel with a screwdriver.
  • Next, Chavez introduces a strategically placed clear plastic panel that facilitates the rebonding of the vinyl panel. Chavez then adds another layer of protective masking tape.
  • With the plastic sheet still in place but not bonded, Chavez carefully puts the vinyl panel in position and begins bonding it.
  • Satisfied that the vinyl panel is perfectly positioned, Chavez slips the plastic sheet out and bonds the vinyl panel permanently in place.
  • Chavez deftly manipulates his scissors to trim the excess vinyl from the panel so it fits perfectly. Chavez continues trimming the vinyl panel until he is satisfied the edge of the vinyl will fit into the pre-existing depression in the door panel.
  • Chavez then gently but firmly works the outer edge of the vinyl into the depression in the door panel. Chavez performs each step in the restoration process to both front doors in turn.
  • Chavez manages to stretch the original vinyl smoothly over the original section it covered, and carefully positions the outer edge into the groove in the door panel.
  • After carefully bonding the trimmed section of vinyl in place, Chavez applies silicone to the seams to lock it in place and prevent the vinyl from “lifting.”
  • Look closely at this restored door panel, a work of craftsmanship utilizing the original vinyl without replacing the dried foam. Although the rear doors have a different configuration, Chavez employed the same technique to restore them.

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How often does a customer roll into your shop with a problem that he wants you to solve for practically nothing?

Whatever your answer to this question, the fact remains that this scenario happens too often.

Take door panels, for example. The average vehicle owner is convinced, based on his very limited experience, that you, the auto upholsterer, should be able to perform your magic on his almost irreparable door panels for just less than 13 bucks an hour to cover materials, labor and whatever profit to which you are entitled. By now, you should be smiling broadly and remembering the many times this has happened to you.

There are, however, techniques to economically repair some door panel problems. These techniques have evolved from vast experience in the industry and the unparalleled creativity of some trimmers and their willingness to “try anything.”

Such a situation happened recently at Bud’s Auto Upholstery in Long Beach, Calif. The customer brought his beautifully maintained 1995 black Audi 90 to shop owner Tom Benson to have the bedraggled interior rebuilt. Apparently, the dozen years of service and the damage done by several “washings” of the interior had left the foam and glue dried and crumbling. Although the vinyl fabric was still in good order, the door panel inserts were flapping in the breeze, and the interior was literally falling apart.

Pricing a rebuild like this with new fabric, new foam and hours of labor could make the average customer cry, especially those guys with that preconceived budget of $13 an hour. Fortunately for this customer, one of Bud’s star upholsterers, Max Chavez, is a 50-plus-year veteran of the upholstery industry and a very inventive craftsman. The accompanying photos and captions show how Chavez put the doors of the Audi back in shape beautifully, without destroying its owner’s pocketbook.

  • This 1995 Audi 90 looks great, runs beautifully and is good on gas, so the owner decided to have the upholstery shop restore the interior, the car’s only real flaw.
    This 1995 Audi 90 looks great, runs beautifully and is good on gas, so the owner decided to have the upholstery shop restore the interior, the car’s only real flaw.
  • After the owner explained his limited budget, upholsterer Max Chavez began by removing the dried foam and glue from the front door panel. Chavez uses a piece of scrap foam to clean the dried foam and glue from beneath the vinyl door panel section.
    After the owner explained his limited budget, upholsterer Max Chavez began by removing the dried foam and glue from the front door panel. Chavez uses a piece of scrap foam to clean the dried foam and glue from beneath the vinyl door panel section.
  • Chavez then carefully loosens the vinyl panel surrounding the door handle.
    Chavez then carefully loosens the vinyl panel surrounding the door handle.
  • The final step in removing the dried foam and glue is blowing off the area using a pressurized air hose.
    The final step in removing the dried foam and glue is blowing off the area using a pressurized air hose.
  • Masking tape is applied to protect the faux-wood trim on the door panel. When Chavez is satisfied that the area beneath the vinyl panel is clean, he prepares to begin the next step. Masking tape is applied to the border of the section to be covered.
    Masking tape is applied to protect the faux-wood trim on the door panel. When Chavez is satisfied that the area beneath the vinyl panel is clean, he prepares to begin the next step. Masking tape is applied to the border of the section to be covered.
  • Chavez then very carefully begins to bond the vinyl section back into position with spray-on upholsterers’ glue. Chavez continues applying the spray adhesive until the vinyl panel and the area beneath it are both saturated.
    Chavez then very carefully begins to bond the vinyl section back into position with spray-on upholsterers’ glue. Chavez continues applying the spray adhesive until the vinyl panel and the area beneath it are both saturated.
  • After the spray adhesive has been applied thoroughly, the protective masking tape is removed.
    After the spray adhesive has been applied thoroughly, the protective masking tape is removed.
  • Now Chavez’s artistry begins as he works the edge of the vinyl panel into the existing depression in the door panel with a screwdriver.
    Now Chavez’s artistry begins as he works the edge of the vinyl panel into the existing depression in the door panel with a screwdriver.
  • Next, Chavez introduces a strategically placed clear plastic panel that facilitates the rebonding of the vinyl panel. Chavez then adds another layer of protective masking tape.
    Next, Chavez introduces a strategically placed clear plastic panel that facilitates the rebonding of the vinyl panel. Chavez then adds another layer of protective masking tape.
  • With the plastic sheet still in place but not bonded, Chavez carefully puts the vinyl panel in position and begins bonding it.
    With the plastic sheet still in place but not bonded, Chavez carefully puts the vinyl panel in position and begins bonding it.
  • Satisfied that the vinyl panel is perfectly positioned, Chavez slips the plastic sheet out and bonds the vinyl panel permanently in place.
    Satisfied that the vinyl panel is perfectly positioned, Chavez slips the plastic sheet out and bonds the vinyl panel permanently in place.
  • Chavez deftly manipulates his scissors to trim the excess vinyl from the panel so it fits perfectly. Chavez continues trimming the vinyl panel until he is satisfied the edge of the vinyl will fit into the pre-existing depression in the door panel.
    Chavez deftly manipulates his scissors to trim the excess vinyl from the panel so it fits perfectly. Chavez continues trimming the vinyl panel until he is satisfied the edge of the vinyl will fit into the pre-existing depression in the door panel.
  • Chavez then gently but firmly works the outer edge of the vinyl into the depression in the door panel. Chavez performs each step in the restoration process to both front doors in turn.
    Chavez then gently but firmly works the outer edge of the vinyl into the depression in the door panel. Chavez performs each step in the restoration process to both front doors in turn.
  • Chavez manages to stretch the original vinyl smoothly over the original section it covered, and carefully positions the outer edge into the groove in the door panel.
    Chavez manages to stretch the original vinyl smoothly over the original section it covered, and carefully positions the outer edge into the groove in the door panel.
  • After carefully bonding the trimmed section of vinyl in place, Chavez applies silicone to the seams to lock it in place and prevent the vinyl from “lifting.”
    After carefully bonding the trimmed section of vinyl in place, Chavez applies silicone to the seams to lock it in place and prevent the vinyl from “lifting.”
  • Look closely at this restored door panel, a work of craftsmanship utilizing the original vinyl without replacing the dried foam. Although the rear doors have a different configuration, Chavez employed the same technique to restore them.
    Look closely at this restored door panel, a work of craftsmanship utilizing the original vinyl without replacing the dried foam. Although the rear doors have a different configuration, Chavez employed the same technique to restore them.

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