Mine are in sad shape (basically falling apart). I've been thinking of using aluminum sheet. I am also considering using 1/4" mahogany plywood (with a clear finish), but I'm not too sure about the 'Woody' look. I ruled out carbon fiber to the the cost. What have people done when they wanted/needed to replace the door panels?

I just remade new ones and covered it in black vinyl

Teflon



vinyl



embossed



padded vinyl



whoa

I have aluminium ones, not too bad. Perspex ones the same colour as the car would look sharp I reckon. Or clear perspex :P

The padded vinyl one is my old ute, anyone seen it around lol, I wanna buy it back!

Anyway, just get foam and vinyl and a backing sheet, its pretty easy to do yourself!
Good luck

I like the padded vinyl one but I'd tweak it a little if it was mine

I used my old vinyl door panels as a template and cut out some new panels from a thin MDF sheet, 8mm I think with a jigsaw. Then I used spray glue and wrapped the MDF in some faux fur type fabric that I liked. Added an orange bead to match my paint color scheme. Can't find my photos of them installed at the moment.

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Yeh i've used 6mm marine ply as it's the same thickness as the original masonite panels. Ya gotta take off a few extra mm on the top and bottom to allow for the panel to slip back into the channels on the door

Ha Ha, the 'whoa' ones are thecrap that was in my coupe.The one behind is my handy work. Used original metal/ply backing piece,spray adhesive on some low density foam, then spray adhesive to black vinyl, stretched over edges and staple gun from behind.