Door panel repair

Double 97

Registered
So there it was…every day. I couldn’t get it off my mind. Nothing I did helped to correct a problem that has been making it difficult for me to enjoy my Mark VIII. I think it’s a common problem; one that many of us suffer from. Now, don’t be embarrassed – it doesn’t make you less of a man (or woman)…it’s just something that we have to deal with.

By now, I’m sure you know what I’m talking about: the upholstery at the top edge of the door panel coming unglued and flapping in the breeze. My first ’97 had this problem when I purchased it at 23,000 miles in 1999 and my second ’97 (which I no longer own – funny story, ask me about it some time when we are sitting around the campfire toasting marshmallows) has the same problem.

I tried all the standard repair procedures including gluing, clamping, making clips to hold it in place. None of this stuff worked in the long haul. Of course, since I am going to be buried in my Mark when I die, repairs for the long haul are the only kind I want to deal with!

So here it is, a way I found of fixing the problem!

I removed the door panel, cleaned away the adhesive that some idiot (me) put there. I then took at 1/16 drill bit and drilled a line of little holes the length of the hard plastic door panel backing. A trip to Wally World’s sewing center (I think you see where this is headed) rewarded me with a pack of sewing needles and some upholstery thread.

My mother, who would be very proud of me now, taught me the basics of sewing when I was a just a young, Mark VIII owner wannabe. At the time, I thought she was trying to give me the skills needed to replace a shirt button or darn socks, should times get tough. Turns out that she was preparing me for owning a Mark…the power of a mother’s love. Wow!

I took needle and thread and silently approached my door panel. I had to be quiet; I didn’t want the imitation animals from which the door panel upholstery was harvested to get upset by the sharp needle headed their way.

I pulled the upholstery firmly into place and began sewing a line. I started at the rear part of the peeled up material and worked my way forward. You’ll notice from the photos, I sewed in a line – not over the edges of the panel and material. I wanted to make sure that the sewing did not cause the material to tear. Additionally, while I drilled a lot of holes, I made sure I didn’t drill too many – if there are too many, it can serve as a “tear along the dotted line” type-thing and tear the material.

Because the front of the panel was worse than the rear, I drilled more holes (closer together) as I moved to the front of the panel.

If I was to do it again (which I will on the Mark I no longer own, man what a funny story), I would do the following:
• Do a better job of picking a thread color – it could match better
• Sew in a straighter line
• Sew closer to the bottom edge of the upholstery material

Because the edge of the panel is tucked into the window molding-thingy at the top of the door, the repair is not visible, so I guess the thread color isn’t so important. But I know it doesn’t match as well as it could!

It has held up very well. I’m going to call this repair a success. Thanks mom!

Ron
 

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That's an ingenious fix! I just used some industrial epoxy and wood clamps on mine, let it sit over night while I was painting parts off the panel and so far mine has held up for 3 months, including leaving the window cracked open in a rain storm!
 
Thanks for the kind words. I had tried a couple of different trim adhesives - one time I even glued it, clamped it, and kept the door panel in the house for a week to allow the glue time to dry. It didn't hold for more than a week or two. I hesitated on using real industrial-type adhesives. I was concerned about the glue melting the pleather! I guess I needn't have worried - it worked well for you.
 
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