Morris Minor Owners Club

Hi I am about to make a pair of door cards for my van , has anyone used any other material other than mdf for the backing boards

hardboard, thin and flexible like the original

Hardboard would last longer with a coat or two of varnish to keep it waterproof.
Were you planning to cover in vinyl or something else ? Thin layer of foam and then vinyl ?
You could always use Millboard
https://www.woolies-trim.co.uk/product/1648/millboard
A well respected trim firm , a satisfied customer , no connection.
Bob

Hi I intend to cover with vinyl was hoping someone had made there's in some kind of pvc/plastic sheet save problems with water ingress

Haven't done it yet, but I was considering 1.5mm PVC or polypropylene sheet as it is more stable in damp conditions. This type of stuff:

http://www.claddingwarehouse.co.uk/hygi ... dget-sheet

You should be able to find a local stockist who might have cut sizes.

Yes that looks like what I am after but will probably use the 2mm thick sheet may have to wait till I get back from sunnier climes cheers

i have redone my door cards using oil tempered hardboard and varnishing both sides twice to protect. then covered in thin foam (Woolies) and then vinyl bonded using Evostick and secured with staples. Very stable and secure. I did try marine ply but this was import Chinese stuff and very poorly made.

Hi. I have purchased 4 pieces of petg 2mm plastic sheet and cut and drilled them to a template door card for my van I am just awaiting from Woolies the non stretch vinyl to cover the cards . Total outlay £20 for the 4 pieces of petg (2 spares ) and £13-50 plus postage for the vinyl

I will be very interested how this turns out. Are you backing the vinyl with thin foam as suggested by 936cbpminor? Might help protect the vinyl at the outer edges.

I am trying to make it look as original as possible the vans didn't have any padding on the door card it was just painted a very light crinkle finish , the outer edges of the door card I have filed a small pencil round

I would think high-density polyethylene would be ideal for the task - stiff, waterproof, easy to cut and form. I'm going to make a glovebox out of the stuff.