Automobile door panels can cost a lot of money. You can save money by constructing your own door panels, and you don't have to be an auto expert. You just have to take the time and effort to learn how to do it properly.
Put one 48 by 48 by 1/8-inch hardboard on top of work surface. Get a previously used door panel and put it on top of the hardboard. Use a marker to draw around the door panel to recreate the shape.
Cut the shape of the door panel out with a jigsaw. Put spray glue on one side of the door panel you have just cut out. Stick some headliner foam firmly down on the panel. Make sure that the cloth part is facing upwards. (See references 1)
Put door panel cloth down on the work surface, put some spray glue on it. Pick up the hardboard and push it onto the cloth. Use your hand to iron out any creases or bumps on the fabric.
Flip the door panel over and pull the cloth tight. Use a staple gun to secure the fabric. The door panel is now ready to use.
Do not push too firmly on the cloth when sticking it to the door panel. This can cause compression of the fabric and ruin the effect of the door panel.