folding door pocket restoration

[robmog]

finally getting around to posting my door pocket restoration technique,
as originally printed in the ESSES magazine.
here's a typical beat up door pocket that i started with.
note the poor condition of the felt flocking and edge delamination.

Also pictured the tools and supplies required: flocking glue, fibers and a sprayer, plastic wood putty, vinyl repair kit, waterproof glue, vinyl color paint.

[robmog]

disassembly:
gently pry off the aluminum trim. be careful not to bend or distort.
you can leave the big corner piece in place. the edge trim can slide out.
notice the vinyl is only glued at the bottom back edges and staple secured.
if the vinyl "floats" it won't telegraph the texture behind it.
remember this fact on reassembly.

also note the crepe paper that covers the rivets this will stop them from showing through

[robmog]

repairs
do your best to straighten trim pieces.
gently spread the channel to allow later re assembly.
if really scratched up you can strip the anodize and polish, then paint.
replacement can be had at einmalig.com

clean your vinyl and removed old glue from backside.
use a vinyl repair kit (jcwhitney.com) to fill scratches, tears and holes.
then use vinyl paint to finish

[robmog]

pocket repairs
this is the challenging part
first use waterproof glue to fix delaminations.
saturate the paper leaves , cover with wax paper and clamp flat.

reattach any broken off pieces and fill defects with wood putty (see pic).

most importantly reshape your pockets, using the arm rest as a contour guide.
a steam iron on its hottest steam setting works great, but don't tell your wife!
blast the steam against the inside and outside surfaces until the fiberboard is soft enough to reshape. take your time here and try to make them flat.
once cooled they will re-harden in the new shape.
lightly sand smooth the spraypaint with clear polyurethane. this waterproofing will stop them from warping in the future

[robmog]

flocking
sand all surfaces to be flocked.
you can purchase the supplies here
http://www.woodcraft.com/search/sear...query=flocking
first apply colored glue, next spray fibers (messy!) and let dry for 72 hours.
the flocking comes in colors if you want to spice it up.
i used basic black
picture shows newly flocked pocket interior and before/after

[robmog]

final assembly
when everything is dry, cover rivets with crepe paper (yes the stuff from a party store, see picture).

attach vinyl with aluminum trim at top and front, remember NO GLUE.
gently pinch the trim to secure the vinyl.

using contact cement glue the bottom edge and the staple to secure.

[robmog]

enjoy your hard work

[karlusmagnus]

Great job Bob. An inspiration to us all, and thanks for taking the time to do a step by step guide.

[pgxif]

super stuff, thanks Bob
do you mind showing how the bungee is threaded through as well please ? many thanks

[mhackney]

Thanks Bob, this is great timing for me! I just removed the door panels and pocket, etc from my 70 S and am planning to R&R the them. One of the trickiest parts - at least to me - is in knowing what they should look like when properly formed and installed! The PO of my car (27 years and he tracked it) screwed the back of the opening pockets to the door to keep them from opening. Of course he did this right through the metal decorative strip at the top of the pocket. My corner metal pieces are in good shape and the pockets may be slightly warped (this is what I mean, I don't know what "right" looks like!). I understand how to contour the top using the arm rest as a guide, the bottoms I am not so sure about. Is there a source for the aluminum top trim strips? Mine are bent, partly missing a 2" part of the end on one, and of course, have holes drilled in to the end closest to the door opening.

Cheers,
Michael