Cracked car door panels are a common problem, often caused by the rigid top felt strip putting stress on the plastic as temperatures fluctuate. While preventative measures exist, many car owners find themselves facing this issue after the cracks have already appeared. Fortunately, repairing a cracked car door panel is a straightforward DIY task that can save you money and restore the look of your car’s interior. This guide provides a simple and cost-effective method to fix those unsightly cracks for under $1.
Before we dive into the repair process, let’s take a look at a typical cracked door panel and the improvement you can expect after this DIY fix.
This image illustrates the condition of a door panel before repair, clearly showing the crack that needs attention. Now, let’s see the result after applying our simple repair technique.
Notice the significant improvement. While not perfectly invisible upon close inspection, the crack is substantially less noticeable, offering a much cleaner look. This repair method is ideal for anyone seeking an affordable and effective solution to cracked door panels.
DIY Repair Guide for Cracked Car Door Panels
This step-by-step guide will walk you through the process of repairing your cracked car door panel using readily available tools and materials.
Step 1: Remove the Door Panel
The first step is to remove the door panel from your car. While detailed instructions for door panel removal vary by vehicle model, the process is generally quite simple. Refer to your car’s repair manual or online resources specific to your car model for guidance on safely removing your door panel.
Step 2: Prepare the Cracked Area
Once the panel is removed, locate the staples near the cracked area on the back of the panel. These staples secure the rigid felt strip that contributes to the cracking issue. Using a Dremel or similar cutting tool, carefully cut the ends off the three staples closest to the crack. This is preferable to pulling them out, which could further stress the panel.
Next, gently bend the felt strip out of the way to expose the plastic panel underneath and access the crack.
Step 3: Drill a Small Hole
Now, take a small drill bit and carefully drill a pilot hole near the crack. The precise location of this hole is important for effectively closing the crack.
For smaller cracks, drill the hole closer to the edge of the panel. For larger cracks, you might need to drill slightly further inward. It may require a bit of experimentation initially to find the optimal hole placement, but with practice, you’ll quickly learn the ideal spot for consistent results.
Step 4: Use a Zip Tie to Close the Crack
With the pilot hole drilled, take a small zip tie and thread it through the hole, positioning it to pull the two sides of the crack together.
Carefully tighten the zip tie to draw the crack closed. Apply firm pressure, but be cautious not to overtighten and risk breaking the plastic panel. The goal is to close the crack effectively without causing further damage.
Step 5: Re-staple the Felt with Paper Clips
With the crack closed and secured by the zip tie, you now need to reattach the felt strip. While standard staples could be used, a surprisingly effective and readily available alternative is a large paper clip.
Cut the end off a large paper clip and bend it into a U-shape, mimicking a staple. Slide this DIY staple into the original staple holes, and using pliers, flatten it against the surface of the plastic panel. Twist the ends of the paper clip on the backside to secure it in place. Start from the inside edge of the felt strip and work your way outwards to ensure proper alignment and secure fastening.
Step 6: Reinstall the Door Panel
After re-stapling the felt strip, your door panel crack repair is nearly complete. At this stage, you can optionally reinforce the back of the repaired area with JB Weld for added durability. This step is not strictly necessary but can provide extra peace of mind.
Finally, reinstall the door panel back onto your car, reversing the removal steps.
Enjoy Your Repaired Door Panels
Here are examples of ebony door panels repaired using this method, showcasing the effectiveness on darker colored panels.
While this DIY repair might not be a perfect, factory-finish restoration, it offers a significantly improved appearance compared to cracked panels. It’s a cost-effective and satisfying solution for car owners looking to address this common interior issue. If you have any questions during the repair process, feel free to ask in the comments below!
