Vanagon – the aluminum obsession continues – sliding door card 

It wasn’t my first choice of materials, but it was given to me by Thomas and I had to use it. 2024-T5 aluminum is hard to weld as I found out with another project. That project might get some air here. I just jumped into it and didn’t pay any heed to the letters printed on the stock, I thought I was just having a bad day at welding. It’s also not happy being bent, snappingly not happy.

So I had a couple of good sized bits of 0.063″ (1.6mm) 2024 that I really couldn’t readily use. Except… my sliding door card had been mangled by the previous owner and although liked the stock vinyl and cloth cover I hated that it was warped and tattered especially at the rear end.

I got that red mist in my eyes and made a replacement card from the aluminum. Yeah I know, it’s not the best stuff for this application. It’s cold, it’s thinner than the stock cards, it’s harder to fab, and I will have to cover with some sort of fabric. Oh speaking of the fabric cover I’m intruiged by this stuff from Seattle fabrics, the link here. I’d stick on a thin layer of open cell foam before the fabric. But we’ll see what I can find, don’t worry it will be covered and slightly insulated.

I just laid the old door card on the metal stock and traced the outline. I popped in holes the same size as stock thinking that maybe the stock clips would hold, but as it turned out they wouldn’t. The aluminum was just too springy to pop conform to the curve of the door without pulling the clips. That meant I had to slightly enlarge the clip holes in the door to accept some 1/4-20 riv-nuts. And then I used 1/4-20 flat head stainless screws and finish washers to attach the panel. And boy oh boy, screwing the door card on is so much more secure than those plastic clips.

The pics follow 🙂

Stock cut with protective plastic film still on.


Yeah, hand cut so the wobblies  show.

A bit of a “hall of mirrors” effect in the van. Maybe keeping it uncovered will make the inside of the van seem larger. 

  1. #1 by Valdoki on June 18, 2017 - 8:58 am

    Good job . 2024-t3 aviation grade aluminium looks so nice .

    • #2 by albell on June 18, 2017 - 9:27 am

      It does look good, nice finish and the protective film worked keeping it that way during fab. Still will cover it. Annoying thing though, I found a bit of nice brown thin leather in my scrap bin that would have been large enough to cover the panel if a corner of it hadn’t been cut out, rats! Might still be usable if I cut it long ways and added a contrasting strip. But I don’t have the sewing skills, andnot sureif wife’s machine will handle the leather. I’ll have to wait till she is out before trying 🙂

      Alistair

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