Join Date: May 2007
Location: Sudbury, Ontario
Melting the ABS pieces together is the best way of doing it IMO. That's what I've done a couple of times in the past. When I do it, I cut some thin strips of ABS from the old door panel and use it as filler, just like welding metal. When you peel back the vinyl, it's a good idea to separate the plastic bottom section of the panel from the top vinyl. Also, when separating the vinyl from the door panel, use plenty of heat on the back site of the panel so that when they separate, the foam and vinyl stay together as much as possible. This way, when you put the vinyl back on the foam will help keep the surface uniform looking.
2011 BMW 335xi (e92) - Black Sapphire Metalic w/ Coral Red Interior