[gtobird]

Originally Posted by XLR8STEVE

I bought through Ames as a PUI door panel and they are Al Knoch products. Looked at them a little more last night. Drivers side fits like a glove. Passenger side does not. Take a look at the photo, I think this is the issue. Drivers side nice crisp angle at the top by the lock pull. Passenger has a sweep. Heard i have to try the heat gun on the back to move it. Also pics of how they hang with no modifications yet. Drivers side hangs nice. Passenger side held out and if you push the bottom, the top by the lock pops out.

Good info. Please keep us posted as to how well you are able to fix this.

Thanks
OJ

[XLR8STEVE]

After stepping away and looking at it fresh, this is how I got the passenger door panel to fit reasonably well.

-Trimmed out the metal overhang to match where the fuzzy window support brackets and the bends on the door inner are located. They were off in 2 spots. The inside edge on the blue tape in the picture is where it will clear the brackets and the bends on the door inner.
-Originally, the rear fuzzy bracket had the inboard metal tab on it. This was hitting also. I cut it off. Drivers side did not need this to be cut.
-Trimmed out the slots where the clips attach to match the door better.

I did not bend or heat the panel. It still sticks up slightly by the passenger lock pull, but not too much to start messing with heating and bending.

[gtobird]

Originally Posted by XLR8STEVE

After stepping away and looking at it fresh, this is how I got the passenger door panel to fit reasonably well.

-Trimmed out the metal overhang to match where the fuzzy window support brackets and the bends on the door inner are located. They were off in 2 spots. The inside edge on the blue tape in the picture is where it will clear the brackets and the bends on the door inner.
-Originally, the rear fuzzy bracket had the inboard metal tab on it. This was hitting also. I cut it off. Drivers side did not need this to be cut.
-Trimmed out the slots where the clips attach to match the door better.

I did not bend or heat the panel. It still sticks up slightly by the passenger lock pull, but not too much to start messing with heating and bending.

Good work!!! This will certainly help me. I have a couple of further questions. I know you talk about heating and bending the panel. I'm wondering if instead of heating and bending you could take a dremel tool with a cutoff wheel and put horizontal slits in just the back plastic piece. Presumably that would allow the panel to bend inward easier. I realize that's also a gamble in that you don't want to damage the panel.

Also, I see you have power windows just as I do. I've already cut out the holes for the window switches but have not installed them. Were you able to get them to stay in place with the clip mechanisms for the switches?

Thanks
OJ

[XLR8STEVE]

Hi OJ, I don't know about the panel cutting. This was my only attempt at this.
I am going to leave it as is. The power window switches come with 2 clips. One has bend tabs to grip the back of the panel (sometimes they werent long enough so they were bent into the foam filler to grip). The second secures the switch into it. They stay pretty well. I decided not to cut and install the rear switches.