r00tnix

So was thinking of learning to play with ABS, to make the door access hole covers for the front and rear doors of a 2018 SCREW 150, and have been doing research on the tools to use etc. I was wondering if anyone knows what the opening sizes are roughly to buy sheets of ABS to cover them? I know I could go large, but was hoping someone took a measurement of what they have done already and would not mind sharing.

Thanks

dhmcfadin

Abs is usually sold in large sheets. It's significantly cheaper that way. Go to your local plastic supply and pick some up. Then measure your door opening. I don't have measurements. I used transfer paper and traced out the shape/size I needed along with bolt holes that avoid any modules or wiring. Then take that to the abs and trace it with a silver sharpie. Then grab your jig saw abs plastic blade and cut it out. Then I use my router table to smooth out all the edges. If you don't have a router, an orbital sander with 80 grit will do the job. Once you make the first one, the other side is even easier.

Hush Car Audio also sells them on this forum. He made mine for my front doors.

HushCarAudio

I buy sheets at my local industrial supplier. I used large transfer tape to outline the hole and then jigsaw to rough size on MDF as a template. I then clean up the edges with a sander for a nice clean curve. I then secure the template to the abs using double sided tape and use a flush trim bit on my router table for a clean finish. If you want to get fancy then edge it with a round over or chamfer bit. Once you locate the mounting holes, I use an insert nut tool and bolts. If you haven't cut with plastic material on the router be very careful. That stuff can run on you quickly.

dhmcfadin

Last part is serious!

r00tnix

thanks guys. Found a spot and ordered a sheet. Takes a few days to get it in, but will see how it goes. Thanks for the tips!

dhmcfadin

Here's the nut riveter I use. Does an excellent job and comes with some rivets to start you off. ABN Nut & Thread Hand Riveter 17-Piece Tool Kit Set - 13" Inch Rivet Setter Gun, Riveting Nuts, SAE & Metric Nose Sets
I'd also recommend running some 1/2" weather strip around the perimeter of the panel to seal everything when you bolt it to the door.

r00tnix

Perfect, I bought the same Nut Riveter, but will get some weather stripping, thanks for that note. Was wondering between weather strip or the butyl rope? Any thoughts between them?

dhmcfadin

Both do the same job but butyl can be very messy. Weather strip won't melt and doesn't smell.

r00tnix

Good point. I will keep with the weather stripping.

artsr2002

What ABS sheet thickness is recommended for making the covers for the door holes? Anyone use MDF to make them instead? MDF sealed with spray on bed liner material perhaps?