A few years ago I made an aluminum door card for the slider door. 1/16” 2024 , I traced the stock card and cut the aluminum by hand. No cnc 🙂
Been using it naked for all this time. But I had bought some olive drab water repellent canvas ( pic says 15 oz, but I recall now that weight was out of stock and I bought 12oz), and the crazy plan was to cover it with that.
Now I say crazy, as why would anyone do interior trimming in olive drab lightly waxed canvas?
Well I wanted that look, and I don’t mind the slight odour the fabric has. Yes, it has the waxed canvas smell.
Oh btw, I made my tintop syncro into a Westy 11-12 years ago using the parts from my ‘82 Westy.
I glued some 1/8” closed cell foam to the panel and then glued the fabric to the foam and wrapped it around the back. I had tested my contact cement a while back, how well would it glue the canvas to the aluminum. I was surprised that it really did glue it well.
The pleats you see in the corner in one of the pics were trimmed flat. Used some fasteners I found online to attached panel to door, they worked well and for the most part reusable (90% removed without damage from the naked panel )
Next day I refoamed and recovered the rear bench. Was way overdue. The stock foam was degrading. I had some 4” foam , but not quite enough to do it properly. Should have 1/2” or so of foam sticking out from the plywood base. I had enough foam to be exact match with plywood , I added quilting stuffing material to pad things out .
Oh and I don’t have an electric carving knife to cut the foam, but a hand held hacksaw blade worked very well
Corners sewn, fabric stapled to back of ply as in the stock 82.
Oh and I used 4” thick foam. I don’t know the density but it’s close to stock. The stuff I took off was about 3.5” thick. But it was old and compressed a bit. But… I think 4” foam might be a tad too thick. It’s tight between the seat back and the base. That’s not a problem sitting, or deployed as bed, but it’s impeding lifting the seat base fully to get to storage . I’m thinking of what to do.
shooftie 