OK I want to make 2 new door cards and re-use my 1966 Deluxe vinyl..
But what should I use?
I went to Bunnings last Sunday and got a sheet of 3.2mm masonite (looks like what the original was), it's been sitting on the BBQ table under cover all week and it's warped up at the ends already!
It is whiteboard masonite, all they had in 3.2mm.

I don't want to use MDF (compressed sawdust) in case it gets wet, but I guess I could coat it in fibreglass resin.

Any ideas? Plywood?

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I've got new door cards in a non Mini and the upholsterer used +/- 5mm thick ply underneath the upholstery. It's holding up nicely.

Marine ply & coat it with something decent before you appolster it

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No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.

Thanks guys.
I have used marine ply for floors in alloy boats, it's pretty stable once well coated with fibreglass resin. Stops it rotting too.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

The this plastic material i used for my door cards. Being plastic it doesnt rot and does a good job. Forgot what its called but its like 2 sheets of plastic with a zig zag look between the two layers, if that makes sense

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Yeah I've seen that stuff, it's used for packing.
Now, where did I see it- ah yes, at Rheem!
4myego, your next mission will be to acquire me some- buddy, pal, maaate.....

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Real Estate for sale signs are made of that stuff, plenty of them about at the moment
Cheers Pete

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A recent study found the average Aussie walks about 900 miles a year
Another study found Aussies drink, on average, 22 gallons of alcohol a year
That means, on average, Australians get about 41 miles per gallon

Kind of makes you proud to be an AUSSIE

That plastic is called corflute.

Don't bother forking out for marine ply, just use cc or cd ply. The only difference between marine ply and structural is m/ply has a thin veneer on the outer layers. Neither is any more water proof then the other.

Personally when i next do my door trims I will be using a product called Forex Classic. It is a high density PVC sheet. Google Halifax Vogel Group and give the nearest branch a call. It might be a bit more expensive but definately one of the better products I have come across. We use it for marine upholstery. You will need a staple gun of some sort as contact adhesives don't hang on to well.

Terry

My neighbour restored a wooden boat recently. The exy marine ply over the cabin is delaminating and buckling already and this is despite a very thick layer of paint over it, along it's edges and underneath as well. He's not a happy chappy at the moment.

yeah, well,,, that`s obviously because it wasn`t sealed properly

marine ply is really good,,, but it`s still wood & will warp & peel & lift & do all the things that wood does when it gets wet, if it`s not totally sealed like the good doc said,,, resin is probably the best thing to use

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No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.

That material is called Coreflute, and is used for signs and the like.
Can be bought from Cadillac Plastics, or found in front of any house that is for sale with a sign!

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Old school panels, canvas cut to size and soaked in varnish , while its still wet it can be molded , it goes hard like a rock , and can be painted, drilled and screwed.

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Yea thats the stuff....got it from bunnings, cheap and doesn't soak water.

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If you are doing a round nose coreflute is too thick and wont fit under the top crome retaining strip. Also be careful when using screw retainers: its easy to collapse under the pressure
When I was at TAFE we were taught to use a thing called Bitumen Board ; its like the original cardboard but is impregnated with bitumen right through the material. Maybe no longer available but Ive used it on a number of cars and its brilliant. Still need to make sure the access holes in the inner door are sealed with plastic. You could try Daleys or Upholstery Distributors at Prospect . UD are the old Cope Musgrove who have been selling materials since the 1920's Both have cash sales at the door

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Mk1 Cooper S
Mini K Rally car

Hey Kev - I used the same stuff as you bought however I sealed it with a wood sealing compund - been sitting in the garage and moved twice in 2 years and still the same as what I bought it - except it is white(the compound goes on really thin so I did 2 coats). It is completely waterproof so will stop the warping when they finally go back into Henry.

Hooroo

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Rob Forsyth
Miniot!!