Door panels pulling off - solved! - ZR-1 Net Registry Forums

secondchance · 05-22-2010

I know a lot of these cars, especially 94 and 95s, have issue w/ door panel slipping off when doors are shut.
Well, since I had door panel off to check door lock I decided to examine what was causing the panel to slip off the top.
Upon careful examination I noticed internal rib molded onto the panel had cracked and separating - this is what shows up as 3 puckers on the outside of the panel. Solution? Heat the back of the curvature w/ a hairdryer set at high as squeezing the curved portion (increase the curvature) and wait for it to cool while holding it in position - problem solved! I may go back w/ some fiberglass matt and crazy glue - best way to fix these door panels (from the back).
As for the door lock, now I am positive it's the tumbler. I guess I will have to order a set w/ new keys.

GOLDCYLON · 05-22-2010

Which the exception of the neat console doors the 94-96 door panels suck. They always crack at the ribbing on the upper back side. The earlier panels do as well over time but it seems the later panels always go first. On the other forum a owner reinfoced each of the ribs with Aluminum cut to fit and epoxy. Seemed to be a solid solution to the floppy door panel problem.

secondchance · 05-22-2010

Quote:

Originally Posted by GOLDCYLON

Which the exception of the neat console doors the 94-96 door panels suck. They always crack at the ribbing on the upper back side. The earlier panels do as well over time but it seems the later panels always go first. On the other forum a owner reinfoced each of the ribs with Aluminum cut to fit and epoxy. Seemed to be a solid solution to the floppy door panel problem.

Once reshaped w/ hair dryer, you can cut fiberglas mat to shape desired, hold it where it needs to be and dab crazy glue over the mat. The rubbery material panel is made of bonds well to mat and crazy glue. I already used this method to tab holes along the bottom edge and it worked real well.

jonszr1 · 05-23-2010

part of the reason we have this problem is we pull the door closed from the top alot,instead of useing the handle in the middle of the panel . i had this problem with my 90 and noticed how i closed the door. i changed the way i closed the door when i get in the car and havent had a problem since . granted they could have built the panels better .......

secondchance · 05-23-2010

Also, looking at how dimples form where ribs are indicates cabin side is in tension. it could be the finish layer shrinks as time goes on.

05-22-2010	#1
secondchance Join Date: Aug 2006 Location: McLean, VA Posts: 3,707	Door panels pulling off - solved! I know a lot of these cars, especially 94 and 95s, have issue w/ door panel slipping off when doors are shut. Well, since I had door panel off to check door lock I decided to examine what was causing the panel to slip off the top. Upon careful examination I noticed internal rib molded onto the panel had cracked and separating - this is what shows up as 3 puckers on the outside of the panel. Solution? Heat the back of the curvature w/ a hairdryer set at high as squeezing the curved portion (increase the curvature) and wait for it to cool while holding it in position - problem solved! I may go back w/ some fiberglass matt and crazy glue - best way to fix these door panels (from the back). As for the door lock, now I am positive it's the tumbler. I guess I will have to order a set w/ new keys.

05-22-2010	#2
GOLDCYLON Join Date: May 2007 Location: Peoria, AZ Posts: 9,153	Re: Door panels pulling off - solved! Which the exception of the neat console doors the 94-96 door panels suck. They always crack at the ribbing on the upper back side. The earlier panels do as well over time but it seems the later panels always go first. On the other forum a owner reinfoced each of the ribs with Aluminum cut to fit and epoxy. Seemed to be a solid solution to the floppy door panel problem. __________________ GOLDCYLON - 91 ZR-1 #2014 GOLDCYLON - 90 ZR-1 #2794, 4L60e (Formerly Schrade's) GOLDCYLON - 11 CTS-V Arizona State Director 91 WHITE/BLACK #2014. 380 P&P&PCed,Ported Heads, Jeal Long tubes, Corsa Exhaust/FIKSE FM-5s /LED TLs, LED Headlights, Front Wilwood 6 piston narrowlite calipers and rear Wilwood caliper street shop mod,CNCed Coolant Pipes,TPI Cvr,Filter cover,Stainless Bolts, DRM/DOM PROM /ZFDOC mod build #102,DRLs,BMAD with stainless Debris Screen,Coplan Air Blaster, Pioneer APP Radio 4,Brey-Krause HB,Sub Bar,Fire extinguisher seat mount,DRM Coilovers,LEDs everywhere,Compass mirror (orange),V1 DIC hidden display, Homelink sun visor, Carbon Fiber top x3 and APSIS Carbon Fiber interior, APSIS CF Steering Wheel/NAPA Leather, Banski trailing arms, Guldstrand front suspension,urethane bushings from Prothane (total suspension) ZFDoc drive shaft safety loop, raptor shift light (orange),AO engineering louver front plate, Console seat cushion, 96CE seats with black custom Sheepskins, ss billet catch can,Viper remote entry/alarm,Cragar Rear Louvers,LED side louver lights, Dewitts Radiator with SPAL fans and a Woods 160 T-Stat 90 RED/BLACK #2794. 4L60e Automatic Stage V by RPM Transmission, TCI Dedicated TCM, OBX Stainless Headers, Corsa Exhaust, SAN Secondaries and Haibeck PROM, Exotic Muscle Coil overs, LED Interior Lights, LED Tail Lights, LED Headlights, 94 Sport seats with black custom Sheepskins , Cragar rear louvers, GS Front calipers, Banski Trailing arms, APSIS Carbon Fiber steering wheel, Front and Rear Baer Eradispeeds, DRLs, Guldstrand front suspension,urethane bushings from Prothane (total suspension), Dewitt's Raditor with Dual SPAL fans and a Haibeck 170 T-Stat 11 RED/GREY CTS-V

05-23-2010	#4
jonszr1 Join Date: Sep 2006 Location: lone pine and mammoth lakes Posts: 1,407	Re: Door panels pulling off - solved! part of the reason we have this problem is we pull the door closed from the top alot,instead of useing the handle in the middle of the panel . i had this problem with my 90 and noticed how i closed the door. i changed the way i closed the door when i get in the car and havent had a problem since . granted they could have built the panels better .......

05-23-2010	#5
secondchance Join Date: Aug 2006 Location: McLean, VA Posts: 3,707	Re: Door panels pulling off - solved! Also, looking at how dimples form where ribs are indicates cabin side is in tension. it could be the finish layer shrinks as time goes on.