R8 3DR Door card repair (With pictures)

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Cromp85
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R8 3DR Door card repair (With pictures)

#1 Post by Cromp85 » Tue Aug 20, 2019 2:53 pm

This is a bit of a tutorial on repairing the Hardboard door cards, as fitted to all 3dr R8 variants.

All 4 door cards on my 220 GSi had started to go soft and out of shape. During my ownership i have tried to stop the material degrading and put them back straight.

After a bit of trial and error, i have got good results using Fastglass resin and P40 fiberglass paste.

The resin soaks in when applied to the soft and flaky areas. This seems to restore the rigidness and stabilise it from further decay. I found it best to jig the panel when curing to ensure it sets in the right shape.

The P40 paste is applied to anywhere the hardboard has come away and peeled off. This strengthens the damaged areas and finishes the repair.

Im about to do the Drivers door card, so pictures to follow soon.
Last edited by Cromp85 on Wed Sep 11, 2019 11:25 am, edited 1 time in total.
My Rovers to date:
1994 Rover 220GSI in Tahiti blue (On the road)
2002 MG ZR 105 in Solar red (On loan)
1995 214i (On SORN)

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GTiJohn
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Re: R8 3DR Door card repair

#2 Post by GTiJohn » Tue Aug 20, 2019 3:51 pm

Looking forward to seeing the pics :clapping
I like Twin Cams.... and Single Cams

Cromp85
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Location: Dudley, West Midlands

Re: R8 3DR Door card repair

#3 Post by Cromp85 » Tue Sep 10, 2019 4:48 pm

Finally got me some image hosting so here are the pics!

The worst bits of damage:
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This is what peeled or crumbled away :scared
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A repair the arm rest/pull handle mount that i did in 2016, Its held up well so no work to do here :D
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Last edited by Cromp85 on Wed Sep 11, 2019 11:27 am, edited 2 times in total.
My Rovers to date:
1994 Rover 220GSI in Tahiti blue (On the road)
2002 MG ZR 105 in Solar red (On loan)
1995 214i (On SORN)

Cromp85
Club Member
Posts: 187
Joined: Fri Oct 02, 2015 11:24 am
Location: Dudley, West Midlands

Re: R8 3DR Door card repair

#4 Post by Cromp85 » Tue Sep 10, 2019 6:47 pm

The repair itself;

I started with the top edge, here it was mostly vinyl with a bit of sawdust.
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I brushed on some resin to fix it in shape.
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Then built it up to the correct thickness with P40.
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It was a bit tricky to get the correct angles, so I worked a few inches at a time. G-Clamps and lengths of timber were used to hold the edges flat while curing.
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Once the top edge was finished, I coated the other weakened areas of the panel with resin.

Front edge:
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Back edge:
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Next step was to use plaster jointing tape and resin for a bit more strength.
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I added P40 over this area in particular as the panel is damaged where the screw goes.
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The finished panel ready to refit :thumbup
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My Rovers to date:
1994 Rover 220GSI in Tahiti blue (On the road)
2002 MG ZR 105 in Solar red (On loan)
1995 214i (On SORN)

Cromp85
Club Member
Posts: 187
Joined: Fri Oct 02, 2015 11:24 am
Location: Dudley, West Midlands

Re: R8 3DR Door card repair (With pictures)

#5 Post by Cromp85 » Wed Sep 11, 2019 12:52 pm

The rear driver side panel which was done first:

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This panel required a lot more reinforcement, probably due to the compicated shape.
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This was by far the hardest bit to get right. A lot of fibreglass was used to make this area rigid again.
I found the angles in this back corner had to be just right, if not the whole panel was out.
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All finished.
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My Rovers to date:
1994 Rover 220GSI in Tahiti blue (On the road)
2002 MG ZR 105 in Solar red (On loan)
1995 214i (On SORN)

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GTiJohn
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Re: R8 3DR Door card repair (With pictures)

#6 Post by GTiJohn » Wed Sep 11, 2019 7:17 pm

Very impressive stuff :clapping
I like Twin Cams.... and Single Cams

richard moss
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Re: R8 3DR Door card repair (With pictures)

#7 Post by richard moss » Wed Sep 11, 2019 10:03 pm

Thanks for posting this
Out in the desert with 2 old Jeeps and a Saab 9-3 cabrio
Back home: wife's 1993 216 DOHC Cabriolet, daughter's R100 and my 1969 MGC GT

Cromp85
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Location: Dudley, West Midlands

Re: R8 3DR Door card repair (With pictures)

#8 Post by Cromp85 » Thu Sep 12, 2019 10:01 pm

A bit i forgot to mention;
You might find the plastic fixings for the rear panels break or are too chewed up to reuse. If you can't find replacements, The door card fixings from a Mazda RX8 are a perfect substitute.
My Rovers to date:
1994 Rover 220GSI in Tahiti blue (On the road)
2002 MG ZR 105 in Solar red (On loan)
1995 214i (On SORN)

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