JBugs Video Series

1970 VW Karmann Ghia - Door Panel Installation:

Video Overview:

The interior swap in this 1970 VW Karmann Ghia is moving along well and we're just about done covering up all the bare areas in the car. We'll finish up the door jambs with some sills to cover the edges of the carpet at the door jambs. Then we'll install some new door check rods so we don't have to use a pair of vice grips to hold the doors open while we're working inside. Then we'll install new tweed door panels, and reinstall the later model padded dashboard. Follow along as our tech continues working on this 1970 Karmann Ghia interior.

Intro: 0:00
Door sill plate installation: 0:10
Door check rod installation: 0:40
Rear quarter panel installation: 2:59
Front door panel installation: 3:51

Video Transcript:

Intro 0:00 Follow along, as we close the door on this door panel installation. Door sill plate installation 0:10 Yes, we are calling this a door panel installation video 0:14 but we have some other things to do as well so we'll start this video where we finish the carpet video. 0:19 By installing door sill plates which finish out the exposed edge of the carpet pieces on the door sills. 0:25 And the driver side sill also covers the main wiring harness. 0:29 Once the sills are set in place, they are screwed in and we can get to working on our doors. 0:35 While we're doing all this though if you would do us a favor and click the like and subscribe buttons. Door check rod installation 0:40 With the sales in place, we can get started by replacing the worn door check rods 0:44 as we're tired of using a pair of vice grips to hold the doors open. 0:48 There is a small tension clip at the top of the pin which can be popped up with a small flat blade screwdriver or knife. 0:54 Or you could just tap the pin down and free of the clip the clips. 0:58 The clips are small and very easy to lose so be careful when popping them off and putting them back on. 1:05 Next, the check rod pin is removed. 1:08 Inside the door, we remove one of the two pins inside the door that holds the rollers in place around the check rod. 1:15 Tapping a punch that is slightly smaller than the pin works great to remove the pin 1:19 and most the time it catches the pin when it comes loose. 1:23 We got lucky on this one as it just caught the edge of the clip. 1:27 The pin is removed along with the plastic roller. 1:30 The old check rod can now be removed and we compare is to the new piece. 1:36 The rubber on the check rod squeezes between the rollers which hold tension on the door to hold it open, 1:41 and the check rod also prevents the door from opening too far. 1:44 The new check rod is installed through the door, with a smoother end sticking towards the door jamb. 1:50 The original plastic roller set in place, 1:54 and the pin is pushed down and back in place to hold it. 1:57 Now the tricky part is getting the tension clip back on. 2:01 The edges of the clip are spread out around the same punch that we used to remove the pin. 2:05 The clip is set in place around the pin and the punch is pulled away from it. 2:10 Then we use the punch to push the clip into place to secure it on the pin. 2:15 It isn't easy to show you inside the door while this is happening, especially with my hands in the way. 2:20 But, we can take a picture once my hands are out 2:22 and you can see the clip in place along with the new check rod. 2:27 Next, we set the check rod in place at the hinge on the door jamb, 2:31 push the pin into place, and reinstall the clip at the top. 2:37 We use a small socket and driver to get it set in place and then push it down with a flat blade screwdriver. 2:44 The same steps are used on the opposite side check rod. 2:47 Our punch did a much better job of catching the clip inside the door. 2:51 We finished with another picture to show that using a punch to install the clip inside the door again wasn't just a fluke. Rear quarter panel installation 2:59 Now, we can get to actually installing the door panels and we're actually going to start at the rear quarter panels. 3:05 After making sure we have a clear path between the carpet and the body for the panel, 3:11 we install the door panel clips into the panel. 3:14 I find a pair of linesman pliers works best, 3:16 and while holding the body portion of the clip I slide the loop portion of the clip into the panel. 3:24 Once the open end can be slid onto the panel, it's pulled towards the edge. 3:28 I normally point all the clips towards the edge of the panel. 3:32 Setting the panel against the body helps as a reference to align the clips once they've all been installed. 3:39 The quarter panel can be slid into place, the clips are further aligned as needed, and the panel is snapped into the body. 3:47 The same process is used on the opposite side panel and then we can get to work on the front door panels. Front door panel installation 3:54 We start by removing the armrest brackets from the old panels. 3:58 With our new panel in hand, we note the various pre-perforated holes in the panel. 4:03 Including; six different arm rest positions, 4:06 holes for early model window cranks and or release levers, 4:10 and of course the two punched holes for the door release lever and window crank. 4:15 They have some cloth material backing covering the holes so we cut it away. 4:20 Using the old panel as a guide, we set the old and new panels together and poke through the 4:25 old armrest holes into the new panel so we know which of the armrest holes we need to remove 4:32 The poked out pieces are pulled from the new door panel. 4:35 A new screwdriver is poked through the door panel material so we can install the armrest. 4:40 After we install all the door panel clips. 4:43 A new armrest is pushed through the door panel, 4:46 and the original brackets are installed under the armrest to hold it in place. 4:51 Now at the car, we install door panel clip seals at all the holes around the door panel opening. 4:58 Here we note that if you plan on driving in inclement weather, 5:01 washing it with a hose, 5:03 and generally don't mind water running through your door, 5:06 you want to install a plastic vapor barrier. 5:09 Like we did on our Super Beetle restoration. 5:12 Since this car was actually missing some seals, 5:15 and the old door panels don't have any water damage, 5:18 we're going to guess this car is fairly well cared for 5:21 and won't be seeing much water so we're not going to install them. 5:26 We set the door panel up to the door and checked the alignment of the door panel clips. 5:31 Then, we set the armrest bracket above the hook on the door and slide the door panel into place. 5:37 We press the clips into the door, adjusting them as needed, 5:42 and once they're all pushed into place, we install the window crank, 5:48 door release trim plate, and finish by snapping in the door finger cover plate. 5:54 The opposite side door panel installed in the same manner. 5:58 We finish off this video by reinstalling the retrofitted late model dash back into place. 6:03 In our next video we'll get the rear seat upholstery installed. 6:07 Until then, thanks for watching and let us know if you have any questions in the comments below. 4:09 NOW PLAYING 元気ロケッツ - Star Line HD Z400N 851K views