Reupholstering E30 Door Cards

[airmanship]

Just redone E30 door cards in black, Unlike modern day door cards which can be broken into several panels when it comes to reupholstering make it easier. Whereas E30 is a one solid panel making it more tricky to wrap correctly.

So, all OEM door cards have been heat molded into place (Using some kind of hydrophilic stamping machine) making it impossible to replicate exactly. So I usual try different sewing methods to imitate the OEM look for the door cards.

Personally nothing is worse then a miss match of door cards and car seats in the cabin.

I just though I'd share a quick before and after images (And a bit in between).


So this was the original with standard leatherette and cloth combined (fairly aged).


Sanding the door panel down - Last thing you ever want is the adhesive to fail.


So here is the horizontal lines which are on the OEM on some cars.


Stitched down on Scrim foam (re-foaming is essential).


Door card panel cut out of auto grade synthetic leather.


Outline stitching.


Wrapped door pocket.


Door card completed in black.

I did the rear too, but didn't want to bore you guys with to many pictures.
Let me know your thoughts on it.

[Tzantushka]

Very nice!

In the full vinyl cards, I think the original door cards are produced using a radio frequency (RF) welding process where the Vinyl is bonded to the scrim foam giving that stitched appearance.

Eventually when the foam separates from the card there’s no real way to match the OE finish unless you have a RF welder and a stitch pattern embossing electrode.

Unless you re-manufacture the covering in the hand crafted method like yours!
Again, very nice.

[airmanship]

Very nice!

In the full vinyl cards, I think the original door cards are produced using a radio frequency (RF) welding process where the Vinyl is bonded to the scrim foam giving that stitched appearance.

Eventually when the foam separates from the card there’s no real way to match the OE finish unless you have a RF welder and a stitch pattern embossing electrode.

Unless you re-manufacture the covering in the hand crafted method like yours!
Again, very nice.

Thank you Tzantushka,

It's very possible they used some sort of welding process. I did a lot of research into in the early days when I started trimming. At my work place they produce a lot of leather goods synthetic and genuine, and often use a large heat press which would emboss the stitch pattern (Kind of very similar to embossed leather).

On the E30 seats they have again used a welding process to put the foam and fabric together.
Unfortunately my method would take 10 times longer then what they used.

Either-way it's an interesting way of doing things when it comes to welding.

Thanks for your input

[Cypriotgeeza]

Very cool

[martauto]

Bore us with more pics and details please,
Great work you are doing , keep it coming please

Mart.

[boxclever1753]

Agree with Mart - please photo-bomb us with your amazing work!