How to fabricate fiberglass door panels

Written by ken hamilton
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How to fabricate fiberglass door panels
Fibreglass door panels allow you to customise your vehicle. (Digital Vision./Photodisc/Getty Images)

Adding fibreglass to your car door panels allows you to change the shape of your car door and add components to your doors, such as speakers or even a second cup holder. You can also fabricate fibreglass door panels just to be able to shape and decorate your door. Although fabricating fibreglass doors usually involves car doors, you can also do this for other types of doors and any other type of surface that you would like.

Skill level:
Moderately Challenging

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Things you need

  • Fibreglass resin and hardener
  • Brushes
  • Staple gun
  • Sandpaper
  • Fibreglass masks
  • Body filler
  • Acetone
  • Cloth

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  1. 1

    Cover with fabric. Start by taking a large sheet of continuous fabric, and use it to cover the entire panel where you want to add the fibreglass. The panel must be removed from the car doorframe. Use staple guns to attach the fabric to the panel. Add staples on the depressions and grooves of the panels so that you will be able to shape the surface of the panels.

  2. 2

    Apply the resin and hardener. Combine the fibreglass resin and the hardener in a large bowl, and mix well together. Add a little bit of acetone, if you are working in a sunny area where the mixture may quickly dry out. Fibreglass resin usually comes with a packet of hardener, but you can buy additional hardeners separately. Apply the first layer with a paintbrush and allow it to dry before adding the next layer. Let dry again and add another layer, until you get the desired thickness for the fibreglass on top of the door panels. Make sure that you use a fibreglass mask while applying the mixture. Fibreglass has a very strong odour.

  3. 3

    Add the mat. Once the layers of fibreglass has been applied , take strips of fibreglass mat and attach it to the surface of the panels, using leftover resin to get the fibreglass mat to stick. The mat is important, since it is what actually keeps the resin intact over time.

  4. 4

    Sand the panels and add the filler. The fibreglass will change into a lighter colour when it has fully dried. After drying under the sun, get fine-grit sandpaper and use it to polish the surface of the fibreglass. There will naturally be small bumps and holes in the fibreglass panel. You can add fibreglass body fillers like Rage Gold to smoothen out the surface. Let the filler dry out and sand again. Once the filler has dried, you can add a layer of primer on the door panel and paint it with whatever colour you want.

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