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How to make door panels out of lexan

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Not sure what you mean. We traced out the old panel onto the wood template and routed out the lexan using the wood template. Were you meaning something else?

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I mean did you ease the sharp corners (edges) of the lexan so that it's not a hard edge when you wrap with vinyl, either with a quarter-round/roundover router bit or by sanding? :)  Seems like you would want to, otherwise you get a very sharp edge that could be more likely to wear or cut through the vinyl

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Ah. I thought that might be what you were asking but I wasn't sure. Yes, I did sand the cut edges down to smooth them out.

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I had to file down the door clip holes some. Just the part where the clip slides into the smaller hole. Tomorrow I plan on putting the vinyl on the new panels. I think I'm just going to use the felt that's on there. Going for it! Stay tuned....

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Got the good vinyl covering off the panels and cleaning them up to put on the new panels

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Getting it glued down

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And they're done. Everything worked out nicely. I used some Goof Off to clean up the 35 years of dirt off the vinyl. If you use it just don't go too far cause the color starts to come off.

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