MG Midget Door Card - Make Your Own

In this video I show how I made replacement door cards for my 1971 Midget.
There are some great videos showing how to make door cards with other techniques, but I wasn't confident enough in my sewing abilities to give some of them a try.

I think that my method gives a decent quality finish that's similar in design to the originals, but with plastic panels instead of the paper stuff they were made from. The old door cards were warped and cracked from getting damp; something I won't need to worry about with the HDPE I used.

The HDPE sheet can be cut with tin snips very easily. If you have straight cuts to make then use a ruler and score the line deeply twice, then bend it over a straight edge and slice the thin remaining bit. It gives a very nice edge, but is still worth sanding to take off the corners.

The vinyl I bought was stretchy in only one direction. This was ok, but if yours is like this make sure to arrange the stretchy direction to be up and down so that it lays into the grooves (of removed foam) better.

Total time to build was about 10 hours, so if you don't enjoy making stuff just buy new door cards as they are only about $120 for a set, plus shipping. I had to recover my other interior pieces and make some that were missing so it was worth it to me. The entire interior set is pretty expensive.

Good luck with your project!