CLUNKBUCKET

There are many numbers of reasons to remove a door panel. At the core of the problem is something behind the panel either broken or in need of upgrade. Electric window motors gone kaput. Weather strips are weathered. A door ding or dent may require convincing on its backside. The list of reasons go on, but the task at hand is always the same. Remove the door panel to get at the problem without busting the panel into pieces.

The first instinct is to grab onto one corner, wedge something under the panel, and pull. This instinct is usually followed by some profanity and whatever poorly chosen tool getting tossed across the driveway. After the neighborhood dogs start barking in chorus comes the realization that the money to be saved by doing-it-yourself has just snapped in half, possibly three. Replacement door panels are usually a dealer or salvage item and always pricey.

Removing and installing a door panel while keeping it intact is a genuine case of the right tools for the right job. The problem is out of sight. Hidden behind the panel are all manner of fasteners holding the panel in place. While the panel is rarely strong enough to withstand any ham-fisted prying or bending, the fasteners are strong enough to hold onto the panel right up to the point where it snaps. The solution? A set of plastic door panel and trim removal tools that cost a heck of a lot less than a new door panel.

The first step is to remove everything connected to the door on top of the panel. Window cranks, armrests, and anything else with roots in the door. Scour for every screw and clip. Finding the fasteners can be tricky.

Keep an eye for hidden fasteners. This window crank has a clip to hold it in place. Attempting to pry it off without removing the clip would have damaged the panel and possibly snapped the handle.

Figure out which tool out of the set is the best one for the job. The right one will slide under the panel and grip the fastener. The first fastener is the hardest, and the easiest place to cause damage.

Work along the length of the door panel. Remove one fastener at a time. Vehicles that have seen a few less presidents will likely employ more space age materials then the vinyl covered pressboard panel seen here. Modern panels are just as easy to break.

With the panel removed repairs can now be made. Be careful not to tear the plastic attached to the door. The plastic must be put back in the same place to prevent moisture damage. Shown here are all the parts removed and the tools required.

After repairing the fussy window register or expired electric window motor it's time to put the panel back on. Apply pressure and gently push the fasteners one at a time into the door.