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sciroccosteve · Joined: 16 Apr 2012 Posts: 215 Location: Rochester, NY

Hey now,

My interior rear panels have peeled back and away from the window. Has anyone come up with a way to reshape them nicely?
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1979 924
2000 V6 Passat
"Let the fools have their tar tar sauce."
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Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

I've thought of replacing the cardboard backing with a different material. . .haven't got around to execution, tho.
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WeiBe (1987 924S 2.5t) - 931 S3

sciroccosteve · Joined: 16 Apr 2012 Posts: 215 Location: Rochester, NY

!tom · Posted: Mon May 28, 2012 2:01 am Post subject:

Fiberglass?
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78 924 NA
5-lug

txjake · Joined: 17 Feb 2007 Posts: 395 Location: Oklahoma City OK

Hair cell ABS plastic would most likely work.

http://www.chokes.com/ABS_Sheet.html

Kens_74_911s · Posted: Thu Mar 07, 2013 7:32 am Post subject: panel repair options

I have had some success clamping the panel face side down with the proper contour blocking from below etc. then brushing fiberglass resin on the panel. In really beat up areas you can pull some fiberglass matt apart and layer that in place. It does a pretty good job of stiffening things up to maintain the desired profile. I wouldn't do it where the backing is all the way through without putting some foil tape between the backer and vinyl. I suspect the vinyl could then be pulled and brush resin on opposite if needed to make a composite of sorts.
I have a 944 door card that looks pretty soft in one spot. I may work on that this way and post some pictures. The 944 door cards also fail where the power mirror switches attach, That area in F/glass puts back material needed for retaining screws to grab.

Working in ABS sheet is a challenge without vacuum forming equipment. Polystyrene sheeting is less expensive and takes to thermoforming well. I experimented with a sheet bought to fabricate a spoiler lip. It was a challenge to get the heat evenly distributed then and push the contour evenly. To much heat or pressure and it stretches to far and really won’t go back to the shape you were trying to get. I could see sheet material working with gradual bends maybe simplify the curves in the area that is shaped like an arm rest and where seat belt passes through.
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