Brian1
Elite Explorer
- Joined
- February 2, 2000
- Messages
- 5,384
- Reaction score
- 632
- City, State
- Albuquerque, NM
- Year, Model & Trim Level
- 1991 XLT
- Callsign
- KG5BAQ
Over time the plastic skeleton inside the door panel arm rests break down and become loose or even fall off. I recently had this happen and it wasn't the first time. Before, I had just got another used one from the junkyard as new ones are no longer available. This time I decided to make my own.
Materials:
Strip of wood minimum 3" wide x 12" long and 1/2" thick.
Vinyl strip 6" wide x 15" long
Block of foam padding
Cardboard for making a template
Spray can of adhesive glue
3 of 1/4-20 bolts x 3/4" long
3 flat washers
3 of 1/4-20 Tee Nuts for wood 3/8" barrel length
blue thread locker (optional)
sand paper
black spray paint (optional)
Tools:
Sharp scissors
Pencil
Wrench or socket for bolts
Hammer
Mechanical or electric staple gun loaded with 3/8" long staples
Drill with 1/4" and ~5/16+" drill bits
Jig saw
Remove what is left of the arm rest from the door panel. Place a piece of cardboard on the panel and trace the shape the arm rest needs to be to match the door.
Transfer the template shape to the piece of wood and cut it out with a jig saw. Give it a light sand and slightly round any sharp corners and edges. At this point I chose to spray paint my piece of wood black which is entirely optional.
Hold the piece of wood in place and drill from the backside 3 holes that will be used to bolt it on to the panel. Consider the room needed to fit the washers. Drill the holes 1/4" or slightly larger to fit the bolts. Finish drilling the holes in the wood to the diameter needed to fit the barrels of the tee nuts, usually 5/16" to 3/8". On a solid surface hammer the tee nuts into the wood being careful not to split it. The flange will be pointed up once installed.
Materials:
Strip of wood minimum 3" wide x 12" long and 1/2" thick.
Vinyl strip 6" wide x 15" long
Block of foam padding
Cardboard for making a template
Spray can of adhesive glue
3 of 1/4-20 bolts x 3/4" long
3 flat washers
3 of 1/4-20 Tee Nuts for wood 3/8" barrel length
blue thread locker (optional)
sand paper
black spray paint (optional)
Tools:
Sharp scissors
Pencil
Wrench or socket for bolts
Hammer
Mechanical or electric staple gun loaded with 3/8" long staples
Drill with 1/4" and ~5/16+" drill bits
Jig saw
Remove what is left of the arm rest from the door panel. Place a piece of cardboard on the panel and trace the shape the arm rest needs to be to match the door.
Transfer the template shape to the piece of wood and cut it out with a jig saw. Give it a light sand and slightly round any sharp corners and edges. At this point I chose to spray paint my piece of wood black which is entirely optional.
Hold the piece of wood in place and drill from the backside 3 holes that will be used to bolt it on to the panel. Consider the room needed to fit the washers. Drill the holes 1/4" or slightly larger to fit the bolts. Finish drilling the holes in the wood to the diameter needed to fit the barrels of the tee nuts, usually 5/16" to 3/8". On a solid surface hammer the tee nuts into the wood being careful not to split it. The flange will be pointed up once installed.