My door panels are in bad shape. Not too bad for an 1987 4runner however. I'm thinking about trying to make or buy door panels. Has anyone made door panels using diamond plate? Is it hard to do? What thickness would one use? Any help or pics would be great!!

Asked the same q. awhile back; check it out.

Door panel fab

NAPA has what's called a button book if you need bits/pieces.

I used 1/8" aluminum DP to make panels for my Heep. 1st off this stuff is around $20.00 per sq. ft, so you need to get it right the first time. I used the OE panel as a template and did some triming to make it right. To fasten it to the door I used some stainless undercut head screws I got at Fastenall and countersunk the holes, looks trick. You can get the countersink there also. I used a jig saw w/bi-metal blades to cut them out, a belt sander to smooth out and polish the edges and a uni-bit to make the window winder hole. For the door handle opening, drill holes in the inside corners just bigger than the jig saw blade and carefuly cut. To polish the edges, start out w/corase grit and graduate to a finer belt. Use WD 40 or something like it to lube the sanding belt, keeps it cool, lasts longer.
Good luck! Post pics. <img src="/forums/images/graemlins/cheers.gif" alt="" />

Made these door panels out of plastic(Cardboard looking). Just traced out the panel...Lay your cloth or what ever your going to use. Leave a extra 2 inches hang over...spray uphostery(Glue) over the top panel. place the materal on top. then flip it over and glue the flaps over on the back side. I used my soldering gun to make small holes so the sheet metal screws won't pull on the Cloth/materal.

Total cost $5.00 for the Auto uphostery glue.
Plastic Panels(Cardboard looking)-Free From work.
Camo- Free already had laying around.
Time- about a hour per door. Fab & Installed.

Nice! Different. <img src="/forums/images/graemlins/kewl.gif" alt="" />You gettin' out on the trails this summer?