How to Fiberglass a Door Panel

Fiberglass door panels are lightweight and extremely strong. Unlike the metal that typically makes up door frames, fiberglass does not rust and makes an ideal material for areas that experience extreme weather conditions. While fiberglassing a door panel might seem like a challenging task, you can actually accomplish it quite easily. Fiberglass your door panel when repairing dings, rusty spots or other blemishes.

Instructions

Wrapping Your Door Panel

1

Remove all the screws and fasteners holding the door panel in place with a screwdriver. Remove the door handle by removing the bolt underneath the handle and the five bolts on the other side of the door.with a wrench. Wrap the fiberglass cloth around the entire backside of the door panels.

2

Use the glue gun to hold the fabric in place around the edges. Use a little bit of glue at a time while you stretch the fabric instead of trying to do it all at once. After the glue has dried, outline the door with a staple gun to further attach the cloth to it.

3

Cut the excess fabric from the edge of the door, as well as anywhere else where you do not want to have fabric, with the utility knife---locations for speakers, for example. Check to ensure you've glued and stapled everything that needs to stay in place.

4

Test fit the panel on your door; if any of the fabric comes into contact with the door, it will not fit once you apply the resin. In this case, continue cutting until you have removed all the necessary fabric.

Applying the Resin

5

Cover anything you want to protect from resin with a tarp, and cover your hands with latex gloves.

6

Mix the resin with the hardener to create a thick paste that you will apply to the door panel. Follow the instructions on the hardener container to determine the amounts of hardener and resin to combine. While mixing the resin, avoid mixing more than 6 oz. at a time. When combined with the hardener, it reacts extremely quickly.

7

Use the brush to coat the entire door with a coat of resin. Apply the resin in quick jabbing motions using a brush with stiff bristles. Apply the resin to the area where the door panel attaches to the door first, which will minimize the risk of shrinkage once the resin dries. Avoid applying the resin too closely around the screws.

8

Place the resin outdoors, and allow it to dry.

9

Reattach the door panel to your car.

Fiberglassing the Door

10

Cut the fiberglass mat into small pieces that will fit on your door panel with the utility knife.

11

Mix a new batch of resin and hardener in the mixing bowl, and apply it liberally to the surface you want to cover. Place the fiberglass mat over it immediately. Continue applying resin and mat until you have covered your door panel. Apply up to three layers of mat at a time before it needs to dry; a well-fiberglassed door panel will incorporate five to seven layers. Apply new pieces to your door panel using the fiberglass roller.

12

Use a power sander to smooth and shape your fiberglass. Do not be alarmed if you develop several pits in the fiberglass while sanding. You will fill these in during the next step.

13

Combine the body filler with the hardener. Follow the instructions on the hardener container to determine the appropriate filler-to-hardener ratio. Fill in the pits with the brush, and sand as necessary. Repeat this process until satisfied with the smoothness of your door panel.