Door cards

[Joe Heath]

New poster! (less than 10 posts)

Anyone know where i can get the original phase 2 door card material or something very similar so i can re-trim my ones? Spoken to renault and they are telling me that the door cards are no longer available, is this correct anyone have part numbers so i can check, or a set of mint ones for sale?

[phase i 16 v turbo]

I can get them but they are £209+ the vat a side.:scared:

[Phoenix Autosport]

hi there, im currently working on molding some reproduction door and rear quarter cards for the 5 turbo which will be available through my company when ready, i have at length looked into being able to put a corded material covering on them and it appears that the only way to do so with any degree of success is to use a 2 part adhesive that is self curing and to press the material on until set using a large press and tooling to match the contours of the cards, i have approached several specialist upholsterers and vehicle trimmers but they are all telling me that you cant get a lasting professional finish with that sort of material when trimming by hand, when trimmed by hand they have to use a contact adhesive which will allow the fabric to pull away from the card in time when used on internal corners, the second problem is keeping the cord pattern anything near straight would be impossible as the fabric will need to stretch to accomodate the shape of the parts,
on the reproduction parts i am looking to manufacture i will be using a more durable flocked finish in a grey as close to the original fabric as possible, as soon as i have the first set ready i will post some images of them on the forum

[Matt Cole]

hi there, im currently working on molding some reproduction door and rear quarter cards for the 5 turbo which will be available through my company when ready, i have at length looked into being able to put a corded material covering on them and it appears that the only way to do so with any degree of success is to use a 2 part adhesive that is self curing and to press the material on until set using a large press and tooling to match the contours of the cards, i have approached several specialist upholsterers and vehicle trimmers but they are all telling me that you cant get a lasting professional finish with that sort of material when trimming by hand, when trimmed by hand they have to use a contact adhesive which will allow the fabric to pull away from the card in time when used on internal corners, the second problem is keeping the cord pattern anything near straight would be impossible as the fabric will need to stretch to accomodate the shape of the parts,
on the reproduction parts i am looking to manufacture i will be using a more durable flocked finish in a grey as close to the original fabric as possible, as soon as i have the first set ready i will post some images of them on the forum



Awesome mate! Just the thing the club needs. We also need to look at all other plastics, door rubbers, body kits etc etc. Plenty of bits are becoming rare/obosolete and need to be looked at.:agree:

[BluntyR5GTT]

with regards to other bits being made, im looking into getting some panels made in fibreglass, eg bonnet,boot,doors, front wings and roof. ill keep you all posted when i hear back from a couple of places

[DaveMayGTT]

Really great to see someone looking into this. I see a big group buy coming on :)

[phase i 16 v turbo]

with regards to other bits being made, im looking into getting some panels made in fibreglass, eg bonnet,boot,doors, front wings and roof. ill keep you all posted when i hear back from a couple of places


I already have the bonnet mold, just need people to get a list together and pay.

[BluntyR5GTT]

thats cool mike what sort of costs are we looking at for bonnet?

eg if we get 5 people or 10 people how much difference is there

[phase i 16 v turbo]

thats cool mike what sort of costs are we looking at for bonnet?

eg if we get 5 people or 10 people how much difference is there


The cost of the material and the daily rate for someone who knows who to use it. I don't know who to do it or I would make them myself, I know a man that might be able to help but he has alot on at the mo building a quarter mile car in his spare time :D

[Phoenix Autosport]

sneak peek !!
door cards prepared and ready for moulding this week
:)
http://www.phoenix-autosport.co.uk/images/IMG_3233.JPG

[Joe Heath]

New poster! (less than 10 posts)

looking good. any pics of material?

[Phoenix Autosport]

New poster! (less than 10 posts)

looking good. any pics of material?

they will be done in an electrostaicaly applied flock coating, hand trimming a shape like the door cards using material and contact adhesive wouldnt be durable, im going to try and get the color as close to original as i can though

[Phoenix Autosport]

update, temporary molds released, from these we will make a set which we can then finish to a far higher level than would be possible on a vinyl covered part so that final molds are perfect
http://www.phoenix-autosport.co.uk/images/first_mould.jpg

[djinuk]

you cracking work there dude, ive said for a while that r5 door cards are 90% shabby and scrapable now.

[WADDIE]

looking good this work so far! :agree: any prices in the air for thoughts??:cool:

[Phoenix Autosport]

thanks for the comments,
price wise i dont have a fixed price yet but i am hoping to get them in around the £300 mark for a pair of front door cards and a pair of matching rear quarter panels both with fixing points to use the original white clips and supplied in a flocked finish as close to the original grey as i can get, but obviously we will have to cost materials and production time once the final molds are made to ensure we dont sell at a loss but i will offer a discount for forum members ;)

[Phoenix Autosport]

started work on the rear quarters to match the door cards, i decided to work off of some plastic phase 1 cards as they are far less flimsy than the phase 2 ones, first task was to brace the edge that fits by the door as it was flexing a bit more than i liked and i wanted to make sure the new parts are totaly straight
http://www.phoenix-autosport.co.uk/images/braced.jpg

next step was to smooth off the speaker grill found on the phase 1 cards, first i etch primed the grill area so that the filler would stick well.
http://www.phoenix-autosport.co.uk/images/etched_grill.jpg

grill now filled and rest of card etch primed
http://www.phoenix-autosport.co.uk/images/grill_filled_etch_primed.jpg

next the hole for the rear pocket / ashtray needed to be blanked for molding, i had to countersink and screw the rear quarter panel down round the edges to get the plastic to sit flat
http://www.phoenix-autosport.co.uk/images/blanked.jpg

screw heads now filled along with all marks/scratches in the original plastic cards, has had 4 coats of high build primer and flatted back between each coat to get a nice smooth finish
http://www.phoenix-autosport.co.uk/images/high_build.jpg

next job to spay them up in 2 pack, colour sand and polish to a nice shiny finish for molding :)

[Phoenix Autosport]

************************************************** *********
UPDATE

rear quarters now coated in 2 pack ready to polish up and mold
http://www.phoenix-autosport.co.uk/images/painted.jpg

set of cards made from temporary molds so that they can be finished to a higher level for making final molds
http://www.phoenix-autosport.co.uk/images/composite_former_1.jpg

work begins on improving the finish with lots of filling and sanding
http://www.phoenix-autosport.co.uk/images/composite_former_2.jpg

[raider_gtt]

New poster! (less than 10 posts)

Anyone know where i can get the original phase 2 door card material or something very similar so i can re-trim my ones? Spoken to renault and they are telling me that the door cards are no longer available, is this correct anyone have part numbers so i can check, or a set of mint ones for sale?

I have a friend that has a pair of front 90spec door cards and I now they were brand new as far as I no he sill has them!

[Phoenix Autosport]

a bit more progress on our reproduction door cards project, realy coming along now


found a fair amount of deviation in the outside edges of the door cards so skim filled the whole thing to make sure it is made totaly straight
http://www.phoenix-autosport.co.uk/images/dc_skim_filled.jpg

sanded back to a smooth even surface all over
http://www.phoenix-autosport.co.uk/images/dc_skim_filled_sanded.jpg

sprayed them up in a high build primer to take out any sanding marks or texture left in the surface
http://www.phoenix-autosport.co.uk/images/dc_high_build.jpg

wet flatted the primer back to an almost polished finish to ensure the quality of the painted finish
http://www.phoenix-autosport.co.uk/images/dc_high_build_flatted.jpg

sprayed up in 2 pack ready for flatting and polishing
http://www.phoenix-autosport.co.uk/images/dc_painted.jpg

[elmof1]

looking good, i'll be interested a set of fronts:agree:

[markey b]

WOW!!!

if u need anyone to 'try' a set in carbon i'll let u put em in my car :laugh:

[Rinzler]

interested - keep up the development..

[gtmatt]

Wow amazing work ,i would love a set of rears keep us all updated great work :)

[gtmatt]

Any news on door cards ?? :)

[Matt Cole]

:agree:excellent job.!

[Phoenix Autosport]

Any news on door cards ?? :)
im currently flatting, compounding and polishing the formers, having to compound them by hand due to their intricate shape and its taking ages :( but the results should be worth the extra effort, will post up more images as soon as i have something of interest to show you all ;)

and a big thanks to everyone for all the positive coments :)

[Alastair]

Excellent work mate!:)

[gtmatt]

Thanks look forward to seeing them keep it up amazing effort

[Joe Heath]

New poster! (less than 10 posts)

How are the cards coming along?

[old skool turbo power]

you cracking work there dude, ive said for a while that r5 door cards are 90% shabby and scrapable now.


:agree:that dose seems to be the case :(mine was in quite a mess so i just got a pair of phase 1 door cards and fitted them,that way they dont look as bad as the phase 2 door cards with mess or dirt marks on them that was in my car.
so far this looks great ill be intrested to see how the finish will be :agree::cool:.

[Chris Beer]

Pre-Order:

1: 45_CB


I really REALLY need a set of those in my life!!

[Phoenix Autosport]

got both front and rear quarters polished and waxed (20 coats put on and buffed off :p)
the speaker holes have been raised using custom made blanking plates so that the final molds will be able to make cards to take original grills or cards with a flat surface where the speakers would be tpo take aftermarket speakers or be blank for track toys.
they are now ready for making the molds but im waiting on a delivery of low shrinkage molding resin for making the final molds.


on the plus side i now have a full up and running flocking workshop at our premises so if anyone wants any parts doing let me know and i will sort you out a deal.
some sample images of parts i have done for a few people so far
http://www.phoenix-autosport.co.uk/images/corsa_b_dash_trims_red_1.jpg
http://www.phoenix-autosport.co.uk/images/astra_g_pillar_trims_2.jpg
http://www.phoenix-autosport.co.uk/products/Flocking/Flocking%20Images/pug_206_centre_console_blue.jpg
http://www.phoenix-autosport.co.uk/products/Flocking/Flocking%20Images/corsa_b_mirror_covers_blue.jpg
http://www.phoenix-autosport.co.uk/products/Flocking/Flocking%20Images/corsa_b_side_vents_blue.jpg

[Goobie]

Any thing more come of these in the end? :)

[Cr23g]

hi there, im currently working on molding some reproduction door and rear quarter cards for the 5 turbo which will be available through my company when ready, i have at length looked into being able to put a corded material covering on them and it appears that the only way to do so with any degree of success is to use a 2 part adhesive that is self curing and to press the material on until set using a large press and tooling to match the contours of the cards, i have approached several specialist upholsterers and vehicle trimmers but they are all telling me that you cant get a lasting professional finish with that sort of material when trimming by hand, when trimmed by hand they have to use a contact adhesive which will allow the fabric to pull away from the card in time when used on internal corners, the second problem is keeping the cord pattern anything near straight would be impossible as the fabric will need to stretch to accomodate the shape of the parts,
on the reproduction parts i am looking to manufacture i will be using a more durable flocked finish in a grey as close to the original fabric as possible, as soon as i have the first set ready i will post some images of them on the forum

Sounds promising, expect a few big orders :)