TR7 Interior door panel replacement troubles

[Thomas]

Am replacing interior door panels on my 1980 TR7 DHC. Having trouble getting the top sill down in the groove. Any help?
Tom

[nick]

It should drop into the glass channel. Some more details of your problem would be helpful.

[Thomas]

I thought so too, i.e. it would just drop into the panel. Doesn't appear it want to go in until I jam it in. (Like hit it with a hammer..jam it in.) Can't figure out what's wrong.
Tom

[Thomas]

Correction. I didn't actually hit the door panel with anything but even hand force doesn't seem to work. (only tempted to hit it.)
Tom

[FI Spyder]

I just put the top down in first with the panel sitting a little way away, then punch in the panel where the clips are. Where did you get the panels from (are they new)? I replaced mine with the ones from VB which had an aluminum reinforcement bonded on the top third to prevent warping from moisture and replaceable rubber seals (that go against the window glass).

[Thomas]

Mine are brand new from Rimmer Brothers, with the aluminum top panels you described.
Have to punch them down huh! These are non a drop in piece.
Tom

[FI Spyder]

Not drop in. They are a little snug. And I was dealing with panel(s) that had the aluminum (top rear) area bent in transit so I had to bend (form) them in or out (can't remember which).

[Thomas]

That crossed my mind. Will check on that. Thanks.
Tom

[whitenviro]

The window rolled down and check the gap to see if there is anything blocking it? You may have to use a scraper or something with a thin blade to reach down in to hold the window outward so it doesn't interfere. I've had those door panels off more times than I want to count. I typically start with the panel held out at a bit of an angle and engage the top lip, then once it is in there, lay it flat against the door. Slap the places where the plastic connectors press into the door and its done.

[darrellw]

Also, I don't think the replacement panels will sit down quite as nice as the originals. The replacements are straight across the top, where as the originals dip to match the contour of the door. Sounds like you might be seeing something more than that, though.

[supercass]

I find the solution is to push the top part down into the recess whilst holding the panel at an angle, as whitenviro says. Once you have done this you can use the leverage provided when fitting the lower part into the clips to fit the seals snugly. The seals need to be a close fit. Also bear in mind you may need to remove and refit / relocate the seals on the new panel, possibly trimming them first, to provide a satisfactory fit. I have to say I found the fit of the new panels to be vastly superior to old ones. As I recall, new original, old original or remodelled improved replacement these were always a bit of a struggle to fit. supercass

[navydiver]

Sounds like something else I need to make a fiberglass mould of! I have a couple of NOS door cards that may be worth sacrificing if I can't find a couple of undamaged used ones amongst my collection.