[kcarlos2000]

This was given to me by the wise Torontofirecaptain. I have yet to complete this mod on the rear doors but wanted to post this since I did not see it anywhere. Good luck happy modding and all the credit for this how-to should be directed to Torontofirecaptain. All I did was cut and paste.

First, be aware that this requires cutting the “new” 300m rear panels and one of two finishes.

First is the joining of a piece of your existing (or spare/scrap) Intrepid panels, and is the easier of the two.

Second is to heat and reshape the 300M Panel. This is more difficult.

STEPS:
1. Flip the panel over on a soft protective surface.

2. using a pair if needle nose or side cutters, remove all of the staples along the rear edge to the join.

3. Using a hair dryer, or other low heat source, warm the leather cover and carefully and slowly peal it back. USE EXTREME CARE – IT WILL TEAR VERY EASILY. ALSO TRY NOT TO STRETCH IT TOO MUCH.

4. For joining the ‘Trep & 300 pieces, take the ‘Trep panel and cut it down the groove at the rear edge, so that you have just the piece with the pointy tip down to the piece that goes under the lower panel. This is what you will graft to the 300M panel.

5. Trim it nice and square and true.

6. Place it on the 300M piece so that the top corner tips line up, as well as the lower piece – use a marker to trace the line on the 300m.

7. Carefully cut that piece off, - don’t damage your leather in the process.

8. trim it so that the trep piece will fit nice and snug, and is lined along the top and smooth where the leather will go.

9. Using some scrap, cut a couple of pieces that can be fitted in the rear, and using contact cement, glue the trep piece to the 300 piece temporarily.

10. when dry, test fit to the car to be sure it will clear the dog leg. If not, trim a bit more & test again until good.

11. You can now finish bonding the two together, either with glue & body filler to smooth any gaps, and add strength to the seam, or you can “plastic weld” using an electric soldering gun and scrap plastic from the Trep panels
When you are happy it is smooth and strong, cover the leather to protect it from over spray, and coat the plastic with contact type cement.

12. I used very thin packing foam as a replacement “pad” layer under the leather, you could leave it, your choice.

13. When the glue is dry, carefully replace the leather over the new piece,
being careful not to stretch or tear it. Care must be used to get it back over the tip of the panel and to smooth out any wrinkles.

14. When you are satisfied with the front being good, flip over the panel
and spray the inside edge and the back of the leather with the contact
cement and carefully fold the leather under the edge to get a tight finish.
Staples are not necessary as long as the glue is good and tight, the
leather will not lift.

Test fit the panel to the door, holding it tight to the front dge of the door itself. Now take the lock release bar and hold it to the panel, and using a marker, mark the lever pivot point. (you can see it is much too long, as the handles are in different places). Using a good pair of vice grips and a pair of good pliers, bend the rod on the mark, getting as sharp of a bend as possible. It needs to match the stock bend at the end of the rod as closely as possible.

You can now install the panel

Method two is more difficult. The panel needs to be cut along the same line as before, but the outside edge is now trimmed. It is heated to make it flexible, and match the curve of the dog leg. It is then bonded as before to the panel and smoothly finished and the leather replaced.

It requires a lot more test fitting and c are in getting the dog leg to fit
correctly and the contour of the edges smooth and even.

Method one is recommended and has been used by at least two others successfully.

I have not listed any tools necessary. I would suspect that you should be able to figure out what to use.


GOOD LUCK

DISCLAIMER!! These instructions are not meant to be a 100% method for this conversion, but rather a guideline that assumes that you have a reasonable degree of skill and understanding of the process involved. Some personal initiative may be necessary, as well as a degree of skill. If you are unsure, then it is advisable to seek professional help from an upholstering shop, or some other source.
The author assumes NO liability of any kind whatsoever for your attempt at this conversion. It is assumed that your purchase of these panels acknowledges the degree of difficulty and your acceptance of the above.

[How-To]

Discussion Here:

http://www.dodgeintrepid.net/forums/...0/#post1319256