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Introduction to Door Panel Building



Rev up your passion for automotive customization with our exclusive class on crafting custom door panels tailored for custom car project. Whether you’re a car enthusiast, a DIY aficionado, or a professional automotive fabricator seeking to refine your skills, this immersive workshop is designed to empower you to transform ordinary doors into extraordinary focal points of automotive design.

In this dynamic hands-on session, you’ll dive into the intricacies of designing, fabricating, and installing bespoke door panels that seamlessly integrate style, functionality, and personalized flair. Led by seasoned professionals with extensive experience in automotive customization, you’ll explore a range of techniques and strategies to elevate the interior aesthetics of your custom ride.


Key highlights of the class include:


Introduction to Door Panel Templating:

Understanding the importance of precise templating.

Demonstration: Creating a clear plastic initial template.


Material Transfer and Preparation:

Transferring templates to chipboard and then to wood.

Hands-on: Use MDF templates to router base panels.


Basic Router Skills:

Learning essential router operations: flush trim, rabbet, and round over cuts.


Constructing the Door Panel:

How to properly install and use clips for assembly.

Building a bracket for the armrest mount, incorporating nutserts.


Layering and Wrapping Techniques:

Techniques for building in layers using foam or hard wrap.

Hands-on:  Wrapping door panel base with an insert cut out.

Option to sew insert.


Armrest Fabrication:

Prototyping and shaping the armrest using foam with block shaping or band saw techniques.

Hands-on: Wrapping and assembling the armrest.


Final Assembly:

Glue in insert and attach the armrest from behind for a seamless look.

Demonstrations on specialized router techniques, including cutting for aluminum mounting brackets and integrated door pulls.


Work for Students:

Students will actively participate in templating, cutting, and assembly tasks.

They will not engage in stacked template routing but will observe the process.



Showcasing advanced template usage and router techniques for professional-level customization.


Student Take Home Project:

Each student will leave with a fully assembled door panel:

Dimensions: Full size panel of 33.7″x16″

Materials Used: 1/8″ MDF for the base panel, 1/4″ MDF for upper panels, 1/8″ PVC for the insert, and prototype foam for the armrest.


Whether you’re aiming to enhance the interior of your custom car, elevate your fabrication prowess, or explore new avenues of automotive creativity, this class provides the knowledge, skills, and inspiration to drive your passion forward. Join us and embark on a journey of automotive customization where every detail reflects your distinct style and vision.


Class location:

Cato’s Custom Upholstery

631 N 700 West

North Salt Lake City, UT 84054


June 7, 2024 8:00amJune 9, 2024 5:00pm

About The Organizer

NC Value Statement: Here at NC we take pride in being the industry innovator. Since 1953, we’ve pioneered the flooring trade with new equipment. We will continue to design and develop revolutionary, quality made machinery. NC differentiates itself from others by simply designing and manufacturing our own carpet binding equipment. While others duplicate, we originate.

Phil Cato
Elevate Your Knowledge with Cato's Custom Upholstery -

Where Quality Meets Craftsmanship