tgray
Veteran Member
- Joined
- Sep 12, 2004
- Location
- Marengo, IL
- TDI
- '02 Beetle, '05 Golf, 2000 Jetta, 2001 Jetta, 2002 Jetta
After years of frustration with the VW door panel failures and the solutions that didn't ever deal with having all the tabs broken off I started drilling screws in from behind. That kind of works but the screws tend to poke through. I also repaired some with through bolts but that doesn't look stock. My son was not happy with me doing that to his car so I tried something new. Some have suggested plastic welding but the welder is likely going to damage the other side you see. Some have suggested melting zip ties but I found this is not very strong and they break off very easy.
This method I invented is fairly cheap, easy and very strong It is a little slow but I found the results worth the effort. Once I melted the worm gear clamp into the plastic it seems stronger than the factory melt and the panel insert is now removable and adjustable in the end.
I used small fuel line clamps made of stainless steel
Cut the screw part off and bend the clamp as shown below.
Heat the clamp red hot while holding with a vice grip.
Immediately push the hot clamp onto the proper spot. I then take a screw driver and mash down the plastic that oozed through. I then take the vice grip off when still hot and soft so as to not break the partially hardened plastic.
Let it cool before pulling on it too hard.
Carefully push the clamps through the insert. I usually start inserting one side and start one clamp. Then just work my way around the panel. Don't over tighten the clamps. If a tab hole is broken I used a flat washer. If the clamp is going to hit the window motor just bend it out of the way before tightening. The bend itself will hold the panel tight. On the Jetta I only had to bend one clamp over on the front doors - all others cleared fine.
I glued on new covers I got on Ebay if you are curious. They were cheap and look really good in the end. They give you glue tape but contact cement looks and acts way better in the end. They tell you to tuck the fabric in without removing the insert but the best way is to remove the insert, clean it up. install the new cover and then put it back using this method. I think this method will last a long time as there is no foam backing with the fabric glued directly to the panel insert.
Try melting a clamp on a place where it doesn't count on an open spot to get the feel. If the plastic flames up just blow it out. Then try pulling it off when cooled down to see how much force it takes.
This method I invented is fairly cheap, easy and very strong It is a little slow but I found the results worth the effort. Once I melted the worm gear clamp into the plastic it seems stronger than the factory melt and the panel insert is now removable and adjustable in the end.
I used small fuel line clamps made of stainless steel
Cut the screw part off and bend the clamp as shown below.
Heat the clamp red hot while holding with a vice grip.
Immediately push the hot clamp onto the proper spot. I then take a screw driver and mash down the plastic that oozed through. I then take the vice grip off when still hot and soft so as to not break the partially hardened plastic.
Let it cool before pulling on it too hard.
Carefully push the clamps through the insert. I usually start inserting one side and start one clamp. Then just work my way around the panel. Don't over tighten the clamps. If a tab hole is broken I used a flat washer. If the clamp is going to hit the window motor just bend it out of the way before tightening. The bend itself will hold the panel tight. On the Jetta I only had to bend one clamp over on the front doors - all others cleared fine.
I glued on new covers I got on Ebay if you are curious. They were cheap and look really good in the end. They give you glue tape but contact cement looks and acts way better in the end. They tell you to tuck the fabric in without removing the insert but the best way is to remove the insert, clean it up. install the new cover and then put it back using this method. I think this method will last a long time as there is no foam backing with the fabric glued directly to the panel insert.
Try melting a clamp on a place where it doesn't count on an open spot to get the feel. If the plastic flames up just blow it out. Then try pulling it off when cooled down to see how much force it takes.