I took the driver door panel off today due to the door handle requiring a super pull due to wear and lack of lubrication. The assembly is worn badly enough to need replacement. The origionally round release pin is worn flat on opposite sides! ( Luckily I have a few spares) The door panel itself was wet, and the lower section is mush. I want to replace the cardboard or whatever the stuff is on the lower part of the panel. I suspect a lot of 240s have this issue due to cheap owners like me who wont shell out the now 70 bucks a set for the outer window seals.
I ordered three sets today for my 240 fleet.!! I recommend anyone who plans to keep one of these cars to inspect them today, and replace them immediatly. The only difficulty is deciding to purchase them. The water leaking in the door panel will cause many problems, much more serious than parting with the 70 bucks.

Anyway, I welcome advice on material used repairing old inner door panels.

I repaired a set of door panels many many years ago. It was on my two 79 242 GT's. I wasn't too concerned about keeping them perfectly original and used Masonite 1/8" and several different fasteners to put them together. I did use close cell liquid foam (sort of like Great Stuff) I sprayed it on parts of the board in order to conture the surface before I spray glued the material on to it. The panels actually turned out rather nice. If you don't mind spending the money, there are several automotive upholstery shops that will make the panels. Just take what's left of the originals and maybe a cutout cardboard pattern of the doors a template. Good luck and use a lot of patience.

Hi Burco,

I've come across door cards like that, but so far I've been able to find replacements easily enough. Used parts are starting to dry up so it might come to a repair at some point.

I recall seeing a tutorial on replacing the lower section but I haven't been able to find it. Maybe someone else can help with that. I remember it was quite involved.

As for material, I think it's called hardboard. Masonite, Uline, and Ambersand are brands that you can Google and they're all available in 1/8 thickness. Sealing them is recommended if they're exposed to water. I always put a coat or two of clear lacquer or polyurethane on door cards that are off the door.

Take care that your plastic vapor barrier is well sealed and that the tails are tucked into the holes in the door panel. The old duct tape has likely dried out and can be replaced with a better product made for plastic sheet. I use Tuck Tape brand that I get in Canada, but there must be something like it available in the US. It's used for sealing plastic vapor barriers on the interior of homes, over the studs and insulation. If the plastic layer on the door is sealed well enough, very little water should reach the door card.

Besides the outer window seal, water an also enter through the clips holding the molding that runs across the center of the door. I usually brush some seam sealer around any of those that I can reach when the card is off.

Peter