Common Inside Door Panel Gen 4 Failure. - Taurus Car Club of America : Ford Taurus Forum
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post #1 of 12 (permalink) Old 10-05-2009, 06:29 PM Thread Starter
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This write up is for the common gen4 failing interior door panel, panel. It is the panel just behind the door handle. After time it comes apart. In my case the panel was coming loose and the material had come looses as well.


I went to the dealer to see if I could just buy the panel. They said while they have a diagram that shows the panel as removable and has it's own part number you can not buy the panel individually. The only thing they could do was to sell me an entire new door panel. Well hell with that. That is when I decided to repair/recover myself.

* This all takes place over a 2 day period * for proper glue drying times
Materials used:
Replacement Door Panal material: color code number was V6470 - Found at local upholstery shop for $21.
Fabri-Tac Permanent Adhesive - Beacon Adhesives - Found a Wal-Mart for like $5.

Loctite Super Glue Brush type - Found at Wal-Mart for $3

Heavy Duty Clamps with Rubber ends - Found at Home Depot for $1 for big clamps and $0.50 for little clamps.
Close Pins - Anywhere for dam near free..
Wood Trim peices - Found at Home depot for like $5. At time of this only came in like 8ft lengths but will fit inside a taurus for the trip home..lol
Razor Blade/Box cutter - Found at home depot for $2 (mine was custom set that I had already)

Removal process:

Start by removing the failing panel. This can be done by GENTLY prying the panel loose. It is glued on so try to move around the panel carefully prying each section loose. The key hear is to be carefull and gentle but you will have to use some force to pop the panel loose.

Removed from Door panel:


Back of Panel after removal:


At this point when I got into the house I sat down to see what was wrong with the panel and to my surprise the peice of material that was loose was just a cover for the carpet material you might see on a not leather model car. Both the different material types had come loose..


Here is a full image of the material I am talking about:


Here is the 2 peices seperated:


Now the actual panel is some kind of foam or as far as I can tell a sprayed on foam. It is so fragile that even touching it will rub the foam off and leave gaps. So try to not touch it and if you do be Extremely Carefull!!


Clean the back of your carpet material as best as you can and the edges of the panel. Take the Crazy glue and apply to the outside edge of the panel. **NOT ON THE FOAM!!!** Just on the edge of the plastic panel where it was sealed before. Here it is with 3 of the sides being glued and held together by the clamps and clothes pins. Also while gluing take care to make it as flat as possible on the egdes. Take my word on this..lol Took 2 tries before I got the edges to be smooth, straight and flat. If they are not then the new material will be lumpy looking when you cover it. Let the panel sit clamped up for 24 hours. I would suggest your use the precut wood trim as I did that the second time and it made it perfect..live and learn


Here is the carpet material reattached and glued on all 4 sides. Top and Bottom:



Now take your old top layer material (Not carpet) and cut a new cover using your new fabric. I had to do this a few times, trial and error. I ended up making mine much wider than the orignal and trimmed it down after ward.
1. Take your panel and apply the Fabri-Tac Permanent Adhesive on the edge and apply a nice thin layer to each side Individually.
2. Take your cut wood trim peices and new material and apply to each side of the panel INDIVIDUALLY working one edge at a time all the way around. Let stand for atleast 24 hours this way. *A tip* If you cut your wood trim peices to the the exact lengths than you can press the edges of the material to a point and trim later. I did this after the 24 hour period but next time will do it at the same time.

What mine looked like with everything holding together with Clamps and close pins:


Here it is with all the clamps and corners glued:
(The bottom left of the panel seems to be bowed out, this is due to a slight warp in the panel. Once in door panel this was not a factor)


Here it is in the door panel:



I than took the door panel off and took the foam out and glued the panel back in by simply squeezing the Fabri-Tac Permanent Adhesive in to the old glued holes. With the door panel off you can actually get the panel in farther and dam near butt the panel to the door panel. I than reglued the foam back to the panel.

In the future you can go to autozone or somewhere that sells door panel type clips and glue the male clip on the back of the panel and glue a femal clip through the square holes and door panel. With the door panel off you could actually make the panel removable. If the glue fails to hold the panel to the door panel this is what I will do and I will update this writeup as well.

Hope this helps someone or atleast saves tham from having to buy the entire panel from the stearlship.

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post #2 of 12 (permalink) Old 10-06-2009, 02:20 AM
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Exclamation

O/T but...
When I saw this:

I couldn't help but remember this:



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post #3 of 12 (permalink) Old 10-06-2009, 10:03 AM Thread Starter
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post #4 of 12 (permalink) Old 11-11-2009, 08:57 AM
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QUOTE (I own a Torres @ Oct 6 2009, 09:03 AM)
Quote:
[/b]
Ok I am on the east cost Ny to be exact.. Few questions.
How do you find out your color code for the pleather?
And what upholstery store should I go to?

I am missing the piece of pleather off my rear backseats door. I just bought the car used and didn't even notice it until I was giving my new baby a scrub down yesterday. Unfortunately the preious owner or whoever didn't save it!! It's starting to do the same a little bit on the other door too but I'll nip that one before it gets bad.

I have been searching high and low just for that piece on line. My only other thought was to scavage local junk yards.

My sable is med brown with the light biege or light tan interior. Thanks
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post #5 of 12 (permalink) Old 11-11-2009, 07:37 PM
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I finally got fed up with it and RTV'd the rear ones back on when they started peeling again. It's the only thing I've tried that's worked longer term, although I haven't tried Gorilla Glue.

If it's the front, and it's the plastic insert panel coming off, remove the door panel and use the plastic weld glue they sell at the hardware store...it comes in two connected tubes that mix when you use it. As long as no one has mangled the vinyl with previous repair attempts, you should be able to tuck it back in with some adhesive and no one will ever know the difference.

Jim S. - Pittsburgh, PA


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post #6 of 12 (permalink) Old 11-15-2009, 12:01 PM Thread Starter
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QUOTE (lismarmis @ Nov 11 2009, 05:57 AM)
Quote:
QUOTE (I own a Torres @ Oct 6 2009, 09:03 AM)
Quote:
[/b]
Ok I am on the east cost Ny to be exact.. Few questions.
How do you find out your color code for the pleather?
And what upholstery store should I go to?

I am missing the piece of pleather off my rear backseats door. I just bought the car used and didn't even notice it until I was giving my new baby a scrub down yesterday. Unfortunately the preious owner or whoever didn't save it!! It's starting to do the same a little bit on the other door too but I'll nip that one before it gets bad.

I have been searching high and low just for that piece on line. My only other thought was to scavage local junk yards.

My sable is med brown with the light biege or light tan interior. Thanks
[/b][/quote]

I just went to a local upholstery shop that does cars etc.. and they used their color, material texture book and we just went out to the car and matched it up. Their book should list a code (I listed the one I used) for your selection (whatever it is..). Good Luck.

Mine is still todate holding up (Crossing fingers). The other side I noticed yeterday is starting to come loose but the material is not as of yet. When this one comes loose enough I am going to try to make some clips for the panel this time. We'll see how it goes.
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post #7 of 12 (permalink) Old 05-17-2010, 06:38 PM
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This needs to be added to the wiki
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post #8 of 12 (permalink) Old 05-22-2011, 01:48 PM
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You can also scrape the foam off of the panels and then glue the vinyl on to the plastic piece underneath the foam. That foam is degrading and the foam powder goes everywhere, it's really nasty stuff. I think the foam degrading actually aids in causing the panel material to come unglued. Either way, nice post and excellent repair methods.
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post #9 of 12 (permalink) Old 05-22-2011, 03:51 PM
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Mmmm bacon adhesive.

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post #10 of 12 (permalink) Old 03-24-2013, 11:12 PM
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Does anybody know where I could find replacement vinyl pieces online? It seems that the last owner of my car threw them away and they're missing off all four doors.
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