I'm in need of making new door cards for my 242 and i think there could be demand from others for something similar. What I am thinking is making a new door card backing out of ABS plastic, replacing the original cardboard/timber like material.

This would be achieved by creating a form which I can then mould a sheet of ABS plastic around using heat, duplicating the original shape.

I could use a sheet of clear perspex to identify all the original mounting holes on the door frame, and then accurately transfer them over to the new door card.

I'm not sure the feasibility of it, but perhaps with some skill and patience the original door card covering could be glued to the new backing. Otherwise new custom trim or run bare plastic.

There could be different options e.g. type/colour of plastic, with a hump as per original or a completely flat door card, with or without mounting holes (e.g. someone doesn't want to cover the door card with anything and wants to use visible screws to attach it to the door frame).

Given their size, the door cards would be to large to post using Australia Post. As such would require pickup from north western Sydney.

No idea on cost yet, mainly just seeing if at this point I should go to the extra effort to make my new door cards in a way that can be readily duplicated.

Any suggestions including where to buy large sheets of ABS plastic around Sydney would be welcome.

    I would take two sets, mine are just bearly hanging in, really water damaged

    I've had my GT for 11 years and I only just acquired a good pair of door cards, so I can imagine there would be a market.

    I have a set of replica backings Angus and my Dad made in the 90s, they are thin marine ply coated with a waterproof coating of some sort, they are attached to the original steel door card cappings. I can get some photos if it would be of any help

    I made a set 20 plus years ago out of I think it was 4mm masonite . I know it was masonite, just the thickness I am not sure of. The trick is to make sure the plastic lining seals the door, they rot because water gets to them. They were done buy a guy with a CNC cutting table. Can't remember wtere. Today the board that real estate agents use for sign could be a starter for anyone who wants to safe weight. The metal strip at the top could keep them straight. not sure of the life of the plastic.

    I've used different options on the old Land Cruisers here; foam core board for the doors on the 45 series here, and for the 70 series the upholstery guy used thin aluminium sheet. Advantage is that both are just flat boards, but it gives you an idea of what is possible.

    I think I expressed an interest a couple of weeks ago? If not - I would be. 🙂

    For my purposes I'd need it to work with the power window door armrest/handles, although I'm about 90% sure these mount to the same holes so no change needed to suit that. I'm also not planning on fitting pockets, but trim could cover any pocket-holes. Potentially the biggest challenge would be how to attach the metal-plus-rubber interior window scraper to the top? I can't recall, how does the curve at the top work, is that part of the fibre-board material or is there a separate piece attached to the window-scraper?

    I would definitely be interested in 3 sets of door cards - one lot for my 142, and two lots for my 242s.

    I see this company is reproducing 140-type door cards in Masonite -
    https://australiandoorcards.com.au/products/door-cards-fits-volvo-144-sedan-145-wagon-1966-1974-quality-masonite-x4

    However, they're not offering 2-door cards, and also 74+ 140 door cards are pretty much the same shapes are 240 units. 140 cards up to 73 are shaped differently at the top lip of the card, because front door quarter windows and different window surrounds in 74+.

    For replacements, I'd like something which has the light weight and at least equal (or better) sound-absorbent quality of Masonite, but which is not as prone to water absorption and disintegration.

    I'm also interested in getting a run of 142/242 rear side window seals done - they've been NLA for years.

    Alright definately appears to be plenty of interest so I will get myself setup to be able to do multiple door trims.

    I'm leaning towards ABS plastic as I think I could do the entire thing as one piece i.e. including the normal bulge and the turnover at the top to hold the window scraper.

    That means it wouldn't requiring the metal part from the top of anything else off an old door trim. Also never have to worry about it getting wet.

    Backup plan, I could definately make them out of masonite and attach a bit of extra timber to recreate the bulge.

    I would be keen in a pair, wouldnt mind a set for the rear trim at the same time🤪

    The rears would be a challenge! My rears are always in better nick than the fronts, I guess rain doesn't get in behind as a normal matter-of-course, and there's much less need to remove & reinstall than the fronts too.

      Forg I guess rain doesn't get in behind as a normal matter-of-course,

      When rain gets behind the rears, there's trouble. Since there's no drainage holes in the sills under the 142/242 rear windows, they have a predilection for trapping dirt and water, which then causes rust in the sill panels and the lower B pillar. The rear seat trim cards tend to hold up better in 242s since Mother Volvo moved away from Masonite and into plastic moldings for them, but the zero drainage water trap problem persisted.

        Certainly not the same level of need as the fronts, but yhe thought had crossed my mind of doing rear trims as well. It would be pretty simple to do out of ABS plastic other than where it dips in for the arm rest. That would require a multi price construction and gluing together.

        Forgoing the arm rest, ABS plastic should be pretty simple and even easier than the fronts

        a month later

        ALSO INTERESTED IN A PAIR OF DOOR CARDS 🙂

        5 days later

        I’m in too, if its lighter than the cardboard and made from thin plastic (black ideally).

        The said bulge (full length of door card) will be the challenge and not to be underestimated, so professional advice on forming this is recommended as jigs, form tool, heat process method for plastic would be required.

        Ah, the door cards: a future project for me, for which I have started to collect the bits.
        All ready in my head, I am planning to broadly follow the two documented projects on Turbobricks, creating a later-style door card, including the coveted plastic door pockets, instead of the original of my 1975 car.

        Sorry, but I won't partake in the plastic project.
        My backing board will be 3mm plywood, as this is more resilient in my experience than masonite, can be stapled and it would hold the tee nuts to hang the door pocket on.
        My LHS door card is in a better condition than the right one, and I hope it can be used as a template.
        The cover has to be replaced too, as it is in tatters plus I hate the baby-poo colour. I have identified the vinyl from Spotlight to use, with a fake suede insert also from Spotlight.
        The bulge/beltline Anthony mentions above will be done by combining a strip of the same ply, plus a strip of thicker self-adhesive foam from Bunnings. As in the Turbobricks projects, I will first staple the upholstery to this beltline and bolt it to the big board, so it will hold the upholstery in the middle, allowing strongly stretching it towards the edges, plus hide the stitching of the vinyl to the suede.
        3-4 other under-way projects plus a long overseas trip means I may realistically not start making these this year.

        14 days later

        I’d be in for buying a set off you for my 1980 242. What’s the time frame looks like typically?

        I’ve got remaking door cards on the todo list for the 242. Just did some for 244 out of Masonite with a costing of fibreglass resin to help with waterproofing.

        How did the plastic build go?

        6 days later

        I have some plastic Ford door cards for my Thunderbird. The window scraper is usually held on with staples and contact. can't remember if the top metal cap goes back in or not. Best way to make would be to make an inner and outer fiberglass or wood mold and press the heated plastic in between giving you any bends or odd shapes like the original. EDIT: Just checked and the Ford door cards are made of ABS. A 1200x1000mm sheet is about $71

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