OK, so this is a bit more of an overhaul than a true restoration, but the first panel is done and it looks sooooo much better than before.
This first picture shows the complete panel with a spare used that is very similar in condition to where the completed panel started.
What a difference! But these aren't going to be perfect. The vinyl is 46 years old and has cracks, chips and other imperfections, and this isn't going to be show care, so I'm cleaning these up only so far, and I drew the line at actually repairing the vinyl.
I started by giving the panel a good wash. From an appearance standpoint, it really didn't have much an affect, but was critical to prep for the dye. I opted to use my old standby, Simple Green, to clean the panel.
Next, I carefully removed the backerboard. It was warped (like almost all of this age) and starting to deteriorate. The lower section of the panel was glued down to the backerboard where the lines are. I carefully separated it using a putty knife, and that seemed to work reasonably well. The staples at the edges came out easily, but the vinyl at the edge is very brittle, so care when working with it for all processes was important.
The last step in removing the backerboard with popping it free of the top steel panel. 22 holes were punched through and the points were stamped flat. I used a long, wide-bladed screwdriver to pop these free. It did damage the board at the holes, but left plenty intact for use as a template.
Once off, I had to decide what to use for the new backerboard. I knew I didn't want to use fiberboard of any kind, so I did some looking. Home Depot had a plastic panel smooth on one side, and pebbled on the other that was slightly thinner than the original board and $25 a 4' x 8' sheet. One sheet is all that is needed.
Probably the biggest impact on the appearance was redying the panel. It was already cleaned, so now I had to remove the old "chrome" finish on the thin rule trim. A little quality time with a flat razor blade and it all came off. Then I taped it off. Using SEM Color Coat in medium heavy coats, the dye covered nicely after just two coats without plugging the pattern, running or sagging.
I carefully traced the old panel onto the new material taking care to flatten it out as I worked, and then cut out the perimeter using tin snips. I could have used a saw, but with a little care I could trim out the panel and make a much smaller mess without having to clear an area and set up with tools. I suspect from the way the material cut it is made with fiberglass. It did score and crack pretty easily and cleanly.
Next, I measured out and drilled the holes for where the panel attaches to the metal cap. 20 of the 22 were in line and evenly space. The last two had roughly 1/8" and 1/4" run out. I drilled the holes to be almost exactly the size of the part that would poke through them. They fit very tightly. To keep from cracking the board, I placed a small deepwell socket over the hole and gently (relatively speaking) tapped them down. Then, using a punch, I flattened the tips back over then panel where I could. As tight as the holes were, I have little fear of the panel popping loose.
Here is a close up of the two holes that were out of line from the others.
The holes for the door handles and window cranks I actually waited to drill out until after I mounted the panel. It seems like I was doing it out of order, but it helped me make certain the holes weren't off. They were 1" dia, so I used a paddle bit which made clean holes with a support board behind the to prevent tear-out.
The holes for the door clips were drilled, and then square cuts were made by scoring and snapping small areas out. They aren't as pretty as the factory, but they work well, and the door clips aren't loose.
Next, using double stick foam tape, I cut thin strips and applied it to the back of the vinyl where it glued originally. We'll see how it holds up over time. The edges got the same treatment with a slightly wider slice and seems to hold quite well. If it holds until they are hung, great!
The last thing I needed to complete was the trim. It needed to math the factory chrome trim, but without having to be removed, and it had to be affordable. After trying a couple of options, I ended up with a sealant tape. The chrome isn't quite a bright as some other options, but it performs much better for my purposes, and is a close match on brightness.
I cut 7/16" strips that I laid after supplying a small amount of water to the trim with a spray bottle first. this makes it easier to reposition if need be without trashing the tape.
The end result? I'm happy. I just need to get started on the next three...
