Door Cards Brought Back From The Dead

[Phoenix Autosport]

http://www.facebook.com/phoenixautosport

Bringing a set of Renault 5 Turbo door cards back from the dead.

cards as they were recieved, fabric had been coloured black with an unknown substance and mould had set in
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash4/395091_459213040792364_1249069197_n.jpg

they were also snapped and broken in several places
http://sphotos-g.ak.fbcdn.net/hphotos-ak-prn1/59611_459212910792377_695350382_n.jpg

with fabric removed extent of damage can be seen
http://sphotos-b.ak.fbcdn.net/hphotos-ak-prn1/523584_459213160792352_1849138796_n.jpg

http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/546802_459213267459008_196326111_n.jpg

with the card clamped together the split was soaked with resin
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/14361_459213377458997_923246332_n.jpg

Next the broken off section was refitted in the same way, cloth was used to back up the join and hold the resin so that it soaked into the structure of the card as it was left to cure
http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/535_459213610792307_1255151022_n.jpg

Top surface shows where the resin has soaked through the card and has been sanded to remove excess
http://sphotos-d.ak.fbcdn.net/hphotos-ak-snc7/602378_459213427458992_681654439_n.jpg

Resin soaked join is actualy stronger than the original structure of the card so should last well
http://sphotos-c.ak.fbcdn.net/hphotos-ak-snc7/311181_459213524125649_1506520244_n.jpg

Damage around door handle hole
http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/544743_459229450790723_2029660558_n.jpg

http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/74716_459229564124045_1357181693_n.jpg

repaired and reinforced
http://sphotos-c.ak.fbcdn.net/hphotos-ak-snc7/396196_459229660790702_127904369_n.jpg

front corner also repaired
http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash3/530718_459229727457362_2047338850_n.jpg

Another crack along the front bottom corner of the door pocket repaired
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/21197_459229784124023_180888283_n.jpg

and reinforced on the back
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash4/486360_459229867457348_1134824182_n.jpg

top edge was badly distorted
http://sphotos-g.ak.fbcdn.net/hphotos-ak-snc7/423090_459454040768264_346316183_n.jpg

Top edge of card was sprayed with a mixture of resin and thinners then clamped flat
http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/66268_459454090768259_874930211_n.jpg

left to soak in and cure overnight
http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash4/484964_459454147434920_780980039_n.jpg

Same process was used on the bottom edge to reduce distortion
http://sphotos-a.ak.fbcdn.net/hphotos-ak-snc7/406920_459454210768247_151121756_n.jpg

resulting top edge much straighter
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/12896_459454390768229_564746278_n.jpg

this speaker grill tab was broken but still present
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/554096_459454247434910_574040153_n.jpg

repaired with resin
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/527293_459454350768233_1181001435_n.jpg

this tab was unfortunately missing
http://sphotos-d.ak.fbcdn.net/hphotos-ak-ash3/557607_459454524101549_1696403302_n.jpg

new tab was fabricated from a couple of layers of dense card and left slightly oversize
http://sphotos-e.ak.fbcdn.net/hphotos-ak-prn1/63145_459454600768208_728285650_n.jpg

tacked in place
http://sphotos-c.ak.fbcdn.net/hphotos-ak-ash3/534006_459454684101533_195105525_n.jpg

soaked in resin and left to cure hard overnight
http://sphotos-h.ak.fbcdn.net/hphotos-ak-prn1/155363_459454750768193_621475956_n.jpg

cured tab reshaped with dremmel to match the original shape and size of the tab
http://sphotos-b.ak.fbcdn.net/hphotos-ak-prn1/60777_459454767434858_197301235_n.jpg

http://sphotos-g.ak.fbcdn.net/hphotos-ak-ash4/430604_459454884101513_624977617_n.jpg

structurally repaired cards ready for epoxy
http://sphotos-b.ak.fbcdn.net/hphotos-ak-ash3/603987_459593367420998_1236141012_n.jpg

First coat of thinned epoxy applied, most of this soaks into the surface of the card sealing it and adding strength to the structure, they have then been sanded to take off any roughness left where the card surface was less than perfect
http://sphotos-h.ak.fbcdn.net/hphotos-ak-ash3/599237_459593447420990_235916929_n.jpg

after some fine filling a coat of thicker epoxy applied to allow for proper refinishing of the surface
http://sphotos-f.ak.fbcdn.net/hphotos-ak-ash3/552405_459593497420985_1622220859_n.jpg

epoxy sanded back and surface flocked in a colour matched grey flock, a vast improvement :D
http://sphotos-e.ak.fbcdn.net/hphotos-ak-ash4/406916_468096916570643_621506060_n.jpg

http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/558970_468096843237317_540915996_n.jpg

http://sphotos-c.ak.fbcdn.net/hphotos-ak-prn1/542739_468096893237312_1347253376_n.jpg


http://www.facebook.com/phoenixautosport

[chris]

Thats amazeing i bet with all the resin makes them much stronger and durable also how long did it take you start to finsh

[Phoenix Autosport]

resin and epoxy definately makes them stronger, also sealed in epoxy they wont deform in the damp like they normally do :) was quite a bit of work, i would guess about 10 hours but had to be done bit each day as parts were needing to be clamped, soaked in resin and left to cure over and over

[chris]

They have turned out amazeing i would of chucked them away well done you will definatly be the one i call when i get mine done :agree:

[gttjames]

amazing amount of work you put in, very impressive

[Danboi2]

they look amazing well done keep up the good work :agree:

[Goobie]

:eek: excellent work there! :agree: what's sort of price is involved in a job like this and what colour options is there buddy? Thanks :cool:

[casper]

Excellent work,will defo be getting mine done over the w:agree:inter.

[Brigsy]

Look superb :agree:

[Phoenix Autosport]

cheers for the comments, price wise prep and flocking of good condition cards is £100 for phase 2 fronts and £50 for phase 2 rears, phase 1 rears can be done but are a fair bit more work so £70 a pair, repairs there are never 2 sets the same but as a rough guide the repair work done on the cards shown would have been about £80-£100 but would take a fair amount of time as you have to do a bit clamp it and leave for 24 hours then do a bit more and repeat, if you want a specific quote send me some pics and i will have a look, colour wise pretty much whatever you want can be done :)

[DaveL485]

Thats some great work right there. I'd send you mine, if I hadn't stripped them out to save weight :D

[DaveL485]

Actually, I want my R9 ones doing at some point....:agree:

[Phoenix Autosport]

Actually, I want my R9 ones doing at some point....:agree:
i can certainly have a go at those for you, been a while since i have seen a R9 but if i remember correctly the cards werent dissimilar to the 5