Door Panel Insert Studs

[DnStClr]

Here's a small dilemma I'm in the middle of-
I'm re-doing the interior of my 87. I used a vinyl covering on the door panel inserts. Here's a pic-



A few of the plastic studs on the backside were  broken  so I drilled them out with the idea of replacing them with 1/4 inch  plastic rods, and then screw the thread-cutter nuts on to the new plastic rods.



But, of course, I can't find anybody who has the plastic rod. SO, l thought I'd make my own using a piece of 1/4 inch plastic tubing slid down over a 3/16 inch dowell.  But that didn't work so well- the nut ate up the plastic tubing.   dumb idea anyway.
Does anybody have a source for the plastic studs that are on the insert panel or have you done this repair with something else that I can use to replace the broken ones?
Sorry about that fuzzy picture. I guess I resized it a little bit too much...
                         

[bd]

Don, I experienced the exact same circumstances nearly 19 years ago.  I tapped the holes and permanently installed 1/4" NC set screws of the appropriate length, using epoxy to firmly retain them in the plastic panel.  I installed the screws so the socket heads were accessible from the back, then backing up the screws with an Allen wrench, used torque prevailing aero nuts and washers to retain the trim panels to the door panel.

[DnStClr]

Hmmm . Wouldn't ya know - I've already drilled out the plastic bosses to 1/4 inch, thinking that I would easily find some replacement stud material. Well maybe I could go with 5/16" set screws.

[bd]

So, use Helicoils or other inserts, such as the brass inserts used in wood....

[DnStClr]

That's the answer- thanks Rich. It looks like a 1/4" helicoil won't leave me enough boss wall tho. .  The boss is .510" dia. and the drill hole for the 1/4' insert is a .375" hole. If I drill for the 1/4" insert the wall will only be @ 1/16" thick.  I'll use a 10-24 insert to get more wall thickness.

[bd]

There ya go!  Post up the results with pics.   

[DnStClr]

Will do. I suppose it's a pretty common problem with re-doing the insert panels. 

[DnStClr]

Well, here's what I'm using- a simple thread insert normally used for wood inserts. I wasn't able to find a 10-24" set screw long enough so I'm using brass screws.


After drilling the holes out to 9/32", I used a 5/16" lag bolt to put some threads in the hole.  I put some threadlocker on the brass inserts and carefully threaded them into the plastic.




I attached the brass screws into the inserts to hold the panel. I had to cut the screws to 1/2" long.


And the finished look- I used a darker colored vinyl so it would match my seat.  If it doesn't work out i guess I"ll start all over with a lighter colored vinyl...

[bd]

That worked out really well!  And, there's no concern about them ever breaking off again. 

Thanks for posting that up, Don.

Chris, this would be a great addition to the Tech section.

[bake74]

     That is a great idea for the brass inserts, if you ever have to work on the panel again, should be easier next time.

[Captkaos]

If you can make a single post of that and leave this here I can move it.
BTW I sell those panels already recovered in seat matching material.  The reason all the other companies can sell it is I sacrificed mine.

I just checked the store and these apparently got dropped from an update or something, but I will add them for the future...

[DnStClr]

I checked the store before I recovered the insert panels. I thought they were there too, but didn't see them.

All posts made into a single one -

[dsgb610]

WOW man this looks amazing. This post is right on time. In the middle of doing my door panels.

[DnStClr]

Have you re-coated the panels yet, dsgb610? I didn't spray a coat of clearcoat like some guys do. I've got a couple of paint chips from handling the panels during install, and wonder if the clearcoat would've protected them better.