some pics of the latest door card mods :)

[Phoenix Autosport]

http://www.facebook.com/phoenixautosport

Had a one of you lot send in some renault 5 door cards for refurbishment and a bit of modification so they could fit their aftermarket speaker grills into them instead of the original plastic grills.

1) these are the grills that the customer wanted fitted into the door cards
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/534943_413562898690712_1963109277_n.jpg

2) lower edges of the cards had a fair bit of water damage so section at a time they were clamped flat and painted with a thinned resin so that it penetrated the card and then set in the correct flat shape
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/487831_413562958690706_1414531183_n.jpg

3) cracks and surrounding area impregnated with cyanoacryalate to restore original strength
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/251820_413563032024032_627651112_n.jpg

4) again area impregnated with cyanoacryalate to restore original strength
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/295405_413563078690694_1363856675_n.jpg

5) this area had 2 cracks, distortion to the shape and a missing fixing so it was clamped in place for teh repairs to be done
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/599926_413563135357355_1489353740_n.jpg

6) area surrounding cracks and where the fixing was missing were soaked in cyanoacryalate, fixing was then clamped in place to set
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/8023_413563252024010_329522622_n.jpg

7) bolster on one side had started to collapse but damage was only in the surface layer of the card with the main structure being intact
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/293231_413563305357338_1512031847_n.jpg

8) cracked area set with resin to prevent any further cracking occuring
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/529456_413563362023999_22950045_n.jpg

9) to mount the aftermarket grills i cut some rings from mdf sheet
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/251803_413563388690663_42514401_n.jpg

10) mounted the mdf rings in the back of teh door cards so that they sit slightly below the level of the normal speaker aperture
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/582692_413563418690660_2063467365_n.jpg

11) view from the top, speaker grill tabs were already missing so it saved me a job removing them :)
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/522040_413563462023989_2012999990_n.jpg

12) edges of the speaker holes had seen better days and were crumbling
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/255203_413563515357317_1597674683_n.jpg

13) edges soaked with cyanoacryalate to make them good and solid
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/527947_413563572023978_579592081_n.jpg

14) edges sanded down and filled as required to restore shaping
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/555864_413563608690641_1062832295_n.jpg

15) blocks fitted to the back of the rings to give something substantial for the grills fixing screws to fit into
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318768_413563675357301_156144874_n.jpg

16) close view
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-prn1/555784_413563718690630_1768238426_n.jpg

17) speaker grill surround trial fitted, internal edges refinished as required
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/552335_413563758690626_1034024927_n.jpg

18) refinished edge
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/395973_413563792023956_1009886631_n.jpg

19 close view with surround in place
http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/483327_413563838690618_1389009885_n.jpg

20) cards coated in a layer of thinned epoxy, this soaks into the surface ensuring good adhesion and allows refinishing of the card surface to improve the quality of finish
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/309427_413563878690614_1686641916_n.jpg

21) surface refinished
http://a3.sphotos.ak.fbcdn.net/hphotos-ak-prn1/560978_413563928690609_1721692883_n.jpg

22) close up of speaker area after refinishing
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/577344_413563955357273_1295303109_n.jpg

23) door cards flocked
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/599943_413563995357269_355854100_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/487874_413564048690597_1881216148_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/165923_413564095357259_1455481346_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/482078_413564165357252_333938492_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/544623_413564212023914_698747326_n.jpg

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-prn1/563953_413564298690572_1005085657_n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/602610_413564365357232_1779915695_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/428806_413564408690561_2102624627_n.jpg

24) with the aftermarket grills fitted
http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/309447_413564482023887_51429554_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/541934_413564548690547_592894828_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/481914_413564635357205_116249448_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/396589_413564695357199_511250994_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/179995_413564778690524_1976167084_n.jpg

http://www.facebook.com/phoenixautosport

[GT Josh]

How much does this cost for 2 cards mate??

[Phoenix Autosport]

for phase 2 parts if you are sending in your parts to be refinished by us and they are supplied with fabric removed, the cost for work would be

prep and flock front cards (pair) £100

prep and flock rear quarter cards (pair) £60

prep and flock door pockets (pair) (inc internally) £40


or have multiple parts done for discounts

front and rear cards together £145

front and rear cards and door pockets together £175


return post is approx £18 by tracked courier

we can also repair collapsed armrest on door cards for £12.50
any repairs of minor cracks are included with flocking but larger cracks or other damage may be charged but price would be quoted before comencing work

[markey b]

do you still have doorcard moulds? i'd be after some carbon moulded ones rather than flat sheet ones

[Phoenix Autosport]

do you still have doorcard moulds? i'd be after some carbon moulded ones rather than flat sheet ones
hi there, i still have the formers but not had time to make the molds from them yet, im not going to be doing carbon from them though as with a high gloss finish they would be far to easy for someone to mold off of and sell cheap copies, its a shame but i have lost a lot of money and development time in the past by doing this and at the end of the day i am a business and need to turn a small profit to survive, the aim is to manufacture from glass composite which is not much different weight wise then supply them all in a flocked finish with proper fixings etc so that people have a direct fit part and so that there are no easy to copy parts in circulation

[Trevhib]

These look the best yet. This is the first time I've seen after-market speakers look/fit as good as the OE grilles. Important as most GTT door cards have the grille fitment tabs broken off by divs who didn't take care refitting them. :sad2:

[Phoenix Autosport]

the oe grills can still be fitted without the tabs, they can just be bonded in place instead, no reason why they need to be removable as the speakers are mounted in the door itself, i expect it was just an easy way for renault to attach them as it required no additional fixings and was quick :laugh:
but they do look good with aftermarket ones and i bet will look even better with the matching tweeters in

[Tony Walker]

love the attention to detail, quality job :agree:

[benj88]

Excellent work mate :agree: will eventually get round to getting mine done

..also love that subtle door speaker cover mod :agree:

[Trevhib]

Yeah but if you bond them on, you then have to take the whole card off when wanting to faff around with your speakers thereafter. Plus, all the ones I've seen bonded on had the glue poking out and just weren't quite right. Not everyone does as good a job as you ;)

[Phoenix Autosport]

im sure i could come up with a way of replacing the odd tab if need be :niceone:

[Trevhib]

I guess like the old Astra dash repairs :)

[Steevo]

This looks amazing, how hard is it to remove the original fabric? (the rears are sagging anyhow)

[Phoenix Autosport]

the fabric is easy to remove, just pull it off carefully, chances are its half off already :laugh:, phase 1 vinyl is an absolute ar5e though so phase 2 stuff is far more suitable :smokin:

[Phoenix Autosport]

http://www.facebook.com/phoenixautosport

some images sent in by the customer of the cards fitted, i wasnt sure if the grills would go when he asked me to do them but they do look sweet

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/s720x720/185456_430375560342779_1786722734_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/578911_430375583676110_1731949150_n.jpg

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/582803_430375620342773_799364491_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/305186_430375643676104_2125351313_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/377257_430375660342769_1795910745_n.jpg

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/431048_430375683676100_1589040613_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/255540_430375723676096_1634328005_n.jpg

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/224627_430375817009420_1760703322_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/527200_430375870342748_1664660826_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/582636_430375910342744_1458431595_n.jpg

http://www.facebook.com/phoenixautosport

[Matt Cole]

Excellent! Definately on my list to do.:agree:

[BILLY-R5GTT]

How much for the whole lot Carl? Everything here plus the dash?

I might try and get my 19 16v cab done too :D

Love the look of it :agree:

[djinuk]

your work is godamn amazing.. as said you will be getting a lot of work from myself next year..

on another note.. is there any way of making the reverse of the cards slightly more water resistant.. reason i ask is i find 90% of r5 door seals leak a lot.. evne brand new ones.. and whilst this isnt a problem as theres like holes at the bottom of the door for it to escape if often finds it way onto the door cards on the way down.

[Phoenix Autosport]

cheers for the comments:agree:


How much for the whole lot Carl? Everything here plus the dash?
you will be looking at about £350 all in for dash, door and rear quarter trims, exact price would be dependant on any repair or modification required but thats about the average with a few minor repairs


is there any way of making the reverse of the cards slightly more water resistant.. reason i ask is i find 90% of r5 door seals leak a lot.. evne brand new ones.. and whilst this isnt a problem as theres like holes at the bottom of the door for it to escape if often finds it way onto the door cards on the way down.
when doing the flocking i can spray the backs of the cards with a very thinned epoxy so that it soaks in and seals the surface, however the best way to stop the problem you describe is to re-fit new polythene door seals to the doors before fitting the cards on as this will also help reduce the level of damp inside the car in wet weather and make it a bit less draughty ;):agree: