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Discussion Starter · #1 ·
This is Robert, from Spain. New to this forum. Hi to everybody. First, sorry for my horrible english.

Recently i bought this model. As always, you buy one thing and some work after, reality is different. This post is about trim panels. Doors have water leak and panels are in a horrible state. Last week i was measuring and drawing to make it new with help of a cnc machine. Not for dutch doors.

Idea is make them from 2.5mm MDF. In this case, i will install a 6x9" speaker instead 6.5". As you can see, every detail is drawed but i plan put some screws in plain sides to make installation more rigid. As soon as i cut and test, i will made drawings public for everybody.

This forum is a great help for everybody and i want to contribute in my way.

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I am going to do this same project then wrap the wood with a half inch of foam and upholster it with white vinyl. Currently learning SolidWorks so I can make the parts and then translate them to the CNC
 

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Discussion Starter · #4 ·
Welcome to the site!

Looks like a good plan, can't wait to see it finished.
Thanks. Will take some pics before, during process and after and post them.

I am going to do this same project then wrap the wood with a half inch of foam and upholster it with white vinyl. Currently learning SolidWorks so I can make the parts and then translate them to the CNC
Learning is a good activity but if your doors are like mine ones, i have no problem to public them. First version could be not too accurate. I´m sure will need some fixes...

Do your doors have any leak as mine ?

Thanks
 

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'93 Astro LT Ext w/ FE3 (RWD), 7 Passenger, Dutch Doors, Med Teal, 4.3 V6
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Thanks! Templates like this will be great for extending the life of these vans!
I would love to have a tried and true template for a do-it-yourself headliner.
 

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Discussion Starter · #7 · (Edited)
Thanks! Templates like this will be great for extending the life of these vans!
I would love to have a tried and true template for a do-it-yourself headliner.
Yes, this is the type of things nobody shares. My headliner needs also restoration. I planned make a new one at first, but....i will try to restore it with fiberglass and if it gets rigid enough, glue new fabric. Will see the result. I see your van hav dutch doors. i´m sorry, but my work won´t do you any good.

Now, if i promise something i´m im debt. Here it is. Reinforcement for a pair of 6x9 JBL Stage2 9634 sepeakers as you can see. If you want more sound, it´s possible to use original plates to install another pair of 6.5 round speakers, but i think this should be enough.

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Speaker fits, lets see if plate fits in door too. I will post template as soon as i test. It must fit in the hole because goes inside. Glued to panel, but inside the door. Sorry, i don´t know how to explain it in best way.

Could be a good idea to seal panel+reinforcement with any type of varnish o somethin like that to avoid problems with humidity. MDF does not like humidity at all.

Time flies, but will try to cut one panel to make first test this afternoon-evening
 

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Discussion Starter · #10 · (Edited)
Finally i cut first panel version. Needs to adjust some things.

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Speaker mount too....but need more work on it. Finally, i decided make a plate similar to original riveted to door. Speaker, panel and grille screwed together to four rivet nuts on the plate.


During draw, i thought that making two independent pockets to store (who knows what) could be a good idea. Have 8cm deep available and can be partially covered with a piece of cargo net.

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Below you can see the state of original panel.

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1992 Astro - Silver / Gray / 4 Wheels
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Oh my, I wish I had the skills back then with Acad to redo my inner panels like you did.
When I had the front doors apart on our Gen I '92, I thought something similar could be done there in the bottom front corner for a nice Hi Perf. 6 1/2".

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We are stuck with Dash Crashers that are nigh impossible to... well... anything.
 

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Discussion Starter · #12 · (Edited)
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A 6.5" just in this place ? ... I don´t know if ther is enough room to insert speaker. They use to have abot 6-7 cm deep. We need to know how much it is when window is down. If not, we can make a overpanel mount and be sure it doesn´t bother foot of passenger. Right side is not so wide as driver is.

Sure you know it, but if not, take a look to this video.



I´m afraid i shoud re-make these panels too. I don´t promise nothing but...

This weekend was lost about working on van. I was preparing a 25kva generator for possible power outages this autumm-winter. I don´t understand anything about this crazy situation to which European politicians are leading us.. Sorry for offtopic.


Hope i could make last version of panels and publish templates next week.Left is almost done, but left is a slightly different.

About top dash crashers...really there is nothing to do. I saw a lot of videos and conclude that the only intelligent (and cheap) thing we can do is cover the entire dash.

After researching a lot, i found this company in EEUU... Custom Molded Interior Auto Parts

But i didn´t see any for a ´92.

...be continued.
 
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