VW Mk4 Door Panel Insert Swap - Zip Tie Attachment Method

How to remove and replace the inner panel of a door card on a Volkswagen Mk4, using Zip Ties to attach the panel.

[@koblih69]

Interesting technique, I've done it several times and it was always enough to heat the sealed pins with a heat gun. After the repair it was only necessary to reseal the pins with solder. It worked the same for both flat and round. I never had to fix a pin.

[@KrisYahner]

Nice transformation. Love the zip tie technique!

[@mechanik1313]

Thank Kris!

[@michaelblacktree]

Simple solution to a common problem. 👍

[@mechanik1313]

I'm happy with the results!

[@mattalki]

Too bad I sold my mk4 last year... I would have definitely tried this. Great solution!

[@johnjohn5137]

I've just got my vw golf mk4. I'm happy with it. Just need to upgrade. I don't think I will never sell it

[@Anthony-mf3pu]

Damn this was relaxing as fuck to watch.

[@arcadioalvarez8344]

Haber colocas el panel entré los plásticos y coges un trozo de plástico y lo vas calentando hasta que se funda y lo echas sobre Las ranuras dél plástico azul Más rápido y menos trabajo Después un cordón al rededor de sicaflex con la pistola de silicona y ya está hermético y seguro

[@mechanik1313]

I first attempted to secure the panel with melted plastic at the tabs but it quickly became a mess and did not seem very secure. Hot glue would not hold up to the hot climate of Souther California, so that was also not an option.

[@kevankevan]

Brilliant!

[@djdarlabeathebest]

Great stitch job using the zip ties! 🧵🚙

[@SidewalkMechanics]

good idea brother working on this now!

[@j.b.1526]

Excellent refit. My ‘04 is on its second recover and they need it again. I was going to try it myself this time to save some coin.

[@mechanik1313]

Thanks! It's a fairly easy process.

[@malvinmagri4439]

Thank You! This was Genius!

[@mechanik1313]

I'm glad that it's working out for other MK4 drivers!

[@usamayala8032]

engineer solution big like pro very smart work well done thanks a lot

[@mechanik1313]

Thanks! It's a rather easy, fun solution and the results are worth the effort.

[@mlodszyahmed]

Excelent idea man, will try it for sure

[@joegonzales4749]

Where did u get the leather?

[@OskarQsca]

I use two compuand gule buts that's really nice idea

[@mechanik1313]

I considered an epoxy but I thought that it would be a mess, I would inevitably get epoxy on the replacement leather panel and I was too impatient to wait for the epoxy to cure. I tried this method first on one panel and it worked with instant gratification, so I just went with it.

[@scottpeters1142]

I probably spent $30 per door on plastic epoxy to do mine.. Wish I'd known about this sooner.. :/ lol Good Vid, thanks for the info

[@mechanik1313]

I considered epoxy, but it just seemed like a mess and I was unsure about how it would hold up in the long run. Glad you like the video!

[@mustangmaniac1983]

Great video, thanks for sharing your solution to a very common MKIV issue. Then again everything on these cars is known to go bad... I have a question for you: What is that tool called that you're using to heat up and pierce through the plastic to make the hole for the zip ties? I've tried looking up soldering iron tips, wood burning tools, glue guns, etc. but came up empty. I need to do this to my GTI door panels and have already run into issues cutting the ends off the old plastic to remove the insert. My utility knife isn't getting them so I ordered some cutters off Amazon, hopefully they'll get the job done...

[@mustangmaniac1983]

Oh, I just found it. I guess I did not do a good job searching the 1st time out. The Weller 15 piece wood burning kit looks like the right tool for the job, part number WSB25WB. I'm going to my local Lowes to try to get one today...

[@mechanik1313]

@@mustangmaniac1983 Correct, it is a wood burning kit, similar to a soldering iron, but with interchangeable tips and different shapes. I think I purchased it from either a Michael's Craft store or a Lowes/OSH.

[@mustangmaniac1983]

@@mechanik1313 Awesome, thanks for replying. I was able to get all of the old insert off but broke most of the plastic tabs instead of being able to cut them off. They were really fighting me and not slicing well even with a new blade in my utility knife. I'm going to try to purchase the wood burning kit today, hopefully I still have enough of the plastic tabs leftover to make the opening for pairs of zip ties...

[@mechanik1313]

@@mustangmaniac1983 Were you able to attach the door panel inserts?

[@MontiAlex]

Great idea with cable ties Thank you

[@mechanik1313]

Thanks! I took inspiration from my mountain bike and the way cable ties hold the brake and shifter cables.

[@Romans5_3-4]

Where did you get the leather and how did you upholster it?

[@mechanik1313]

I found clean leather door card panel inserts at the local Pick-N-Pull yard. I assembled a clean set from 3 different Jetta sedans. The wagon uses a different shaped door card, but the panel inserts are the same, so I swapped in these leather panel inserts into my wagon, from the sedan.

[@salvadormurillo9019]

Hello were did you buy the inserts?

[@mechanik1313]

I found a set of clean door card inserts at my local Pick-n-Pull.

[@tiergibbons6725]

Where did you get the leather material from?

[@mechanik1313]

I pulled the door card inserts from a Jetta in my local Pick-n-Pull. I found some that were in good condition.

[@tiergibbons6725]

@@mechanik1313 thanks a lot for the advice I’ll try and find some. You did a good job.

[@Footzerg]

Where did you buy the replacement panel?

[@mechanik1313]

I purchased the replacement panel from my local Pick-N-Pull salvage yard.

[@ahmedgamal2551]

is it still holding till today or the zip ties broke?

[@mechanik1313]

Yes! The zip ties are still holding strong. I haven't had to do any repairs to the doors since.

[@michaelgusty7064]

how has this held up over the last year?

[@mechanik1313]

The door panel inserts have held up great over the last year! They are still solid. No issues. The padded leather inserts really improved the look and feel of the interior over the sagging cloth inserts.

[@VincenzaV1]

Did you recover them yourself? The leather/vinyl looks like new!

[@mechanik1313]

I purchased replacement door card panels from a Jetta sedan at the Pick-n-Pull. I was able to piece together a clean set of four panels from three cars.

[@emreketencioglu5149]

Golf mk27 volkswagen motors 9 hortumu 24 aküsü açık koltukları açık direksiyonu

[@mattiacarradore4714]

Dove hai preso il tessuto? AliExpress?

[@mechanik1313]

Local Pick-n-Pull. Also known as the junkyard.

[@workoutmonster8923]

How did you remove it for f sakes

[@mechanik1313]

I didn't cover that part because there were already videos that did. If you search for, how to remove a vw mk4 door panel, you should be able do find some instructional videos.

[@michaelricks109]

I cut the glue things or whatever

[@Tenacioustribe]

Absolutely ridiculous comment workout monster bumbaclart

[@branastojanovic6579]

Extra

[@xnx0343]

ı am gonna mini drill to do this

[@mechanik1313]

That sounds like a good idea. Let us know how well it works.

[@TheDustDirtGrime]

Did it work?

[@xnx0343]

yes it works but ı advise to do what u see in this video. cause easy one.. drilling harder, be gentle and slower.

[@TheDustDirtGrime]

@@xnx0343 oh alright , thanks Ill prob try the way that its done in the video

[@niewymyslilem]

Na sylikon pan przypierdol i będzie lux

[@mechanik1313]

I agree! This is more lux than silicon. It's stronger and cleaner to work with.

[@marcos.maitamcdonaghdaniel1874]

do you h8 noise why not just use a dremill lol

[@mechanik1313]

I didn't have a Dremel at the time, but in hindsight I think this is stronger because it doesn't remove any material. When the soldering iron melts through the plastic, a small lip is formed on either side of the hole that reinforces the opening. Maybe a Dremel would work but I think the plastic would be prone to cracking in the long run. And no, I don't like Dremel noise.

[@marcos.maitamcdonaghdaniel1874]

@@mechanik1313 cool bud i get you 1000000 percent on the process but as for myself,,,, hello my name is marco and i am addicted to my power drill,angle grinder,dremill and sawzall and my hammers files vice and anvil are used daily or ill just perrish i quit drinking and they are all my therapy hahahaha lol prob glad your not my neighbor unless you move to mexico lol

[@sotirisstavropoulos5151]

You destroyed the panel lol

[@mechanik1313]

The fabric on the original panel was completely delaminated. It's much better now!

[@GaMARzecetrei]

Foking Fake !

[@jamesrichardson4604]

What a terrible bodge job , unprofessional.