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Fixing busted door skin mount tabs

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  • Fixing busted door skin mount tabs

    If you have ever removed a door skin, likely some of the tabs didn't survive. Here is a means to fix them.

    First sand the break into a regular shape, so you can cut rectangular pieces of glass out and have them fit against the plastic. The picture below is before sanding.
    sanding time.jpg

    Get some rough sandpaper and scuff up the area.
    roughed up.jpg

    Here is the form. It is a flat piece of metal covered with plastic tape as a release agent.
    form.jpg

    other side of form.jpg

    Cut up some fiberglass. Small pieces to butt against the surface you sanded flat before, and 3 large pieces to go both on the tab and wrap around the skin bottom. This is all inside the door of course.
    cloth and acetone.jpg

    Acetone the door skin. Mix up your resin.
    mix resin.jpg

    Lay up the small pieces until you approximately have the thickness of a normal tab. Then lay up the big pieces on the tab and bottom of the door.
    layup.jpg
    '99 SL2, 5SP bought new
    Rebuilt at 204,067 September 2017
    Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
    '98 SC2, 5SP bought 2018

  • #2
    After it cures, remove the form. Make a template from another tab.
    door tab template.jpg

    I made a tool to locate the hole accurately. Measure and check.
    IMG_20200326_213333346_HDR.jpg

    Trim as required to get the clip nut on.
    IMG_20200326_213738084_HDR.jpg

    Many other tabs may be cracked but not broken all the way yet. Cracked or good, a couple layers of glass will help keep them together.
    IMG_20200327_112146088.jpg
    '99 SL2, 5SP bought new
    Rebuilt at 204,067 September 2017
    Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
    '98 SC2, 5SP bought 2018

    Comment


    • #3
      The front tabs were a little trickier to fix. Same idea, less room.
      IMG_20200326_215908758_HDR.jpg

      The form was smaller and there is barely enough edge for clamping.
      IMG_20200327_111907370_HDR.jpg

      Form pulled off.
      IMG_20200327_112243734.jpg

      Trimmed and clip nuts installed.
      IMG_20200327_121043735.jpg
      '99 SL2, 5SP bought new
      Rebuilt at 204,067 September 2017
      Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
      '98 SC2, 5SP bought 2018

      Comment


      • #4
        One more picture showing how the large piece extends to the door bottom. This was a reinforced, non-broken tab.
        IMG_20200327_112124076.jpg

        One other note. The new tab does not have the clip nut anti-rotation features. I am not sure if these were required for the stackup when you tighten the screws. I stuck some thin weatherstripping on the tab area.
        '99 SL2, 5SP bought new
        Rebuilt at 204,067 September 2017
        Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
        '98 SC2, 5SP bought 2018

        Comment

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