INSTALLATION INSTRUCTIONS

1968 1972 Chevelle Door Panels

INSTALLATION INSTRUCTIONS

The following instructions were meant to assist you during the installation of our door panels. Please keep in mind that as vehicles get older there are unforeseen circumstances that may cause you to have to alter these steps to make the panels work on your application. While we are more than happy to answer any questions you may have concerning this installation we do recommend that you have the panels installed by a PROFESSIONAL interior shop. Just to be clear, we define the word PROFESSIONAL as someone who is properly qualified and experienced in upholstery. Step 1 Rear Panels It is necessary to install the rear panels first. After removing the old panels and door seals, set the new panel in place and slide towards the rear of the car for a snug fit. Convertible Models: Please note that convertible rear pieces will vary slightly from what is shown here. Just as with our front door panels, the arm rest or ledge for the rear panel is your responsibility and is not included with the kit. 1968-1969 Models: Pre 70 hardtop models will require an additional piece to adapt the rears to fit your car. These cap pieces are additional and should have been provided with your kit, only if you informed your salesperson of your make/model and year. Pre 70 convertible models DO NOT require this adapter. Step 2 Using a drill and the wood screws provided, carefully drill the two screws closest to the door opening in place. These screws will hold the panel in place over the next few steps.

Convertible Models: Please note if you installing the panels on a convertible model you will only need to install the screws in this step only. Once you have installed these screws, move on to step 5. Step 3 Install the door seal over the bottom portion of the rear panel. This step will ensure your panel is in place. It is not necessary to be mindful of any gapping, as your carpet will cover and conceal any such gaps. Step 4 Using a drill bit, pre-drill the mounting holes on the bottom right and upper right sections of the panels (your choice of location). Once pre-drilled, use the provided self tapping, pan head screws to secure the panels to the car.

Step 5 Each set of door panels was shipped with wood sections designed to be wrapped and installed in the depressed areas of the panels. Test fit panels before wrapping or trimming. Upon first test fit, mark area of wood section to be trimmed (area nearest door jamb). It is important that you take into consideration the type and amount of foam/material you will be wrapping this piece in. These variables will determine the amount of trimming you need to do. Step 6 Front Door Panels Line up the provided template along the bottom and hinge edge of the door as shown. It is highly recommended that you lay a large layer of painters tape along the edges of your inner door for protection. Door Speakers: Please note: door speaker installation is optional. If you elect not to install door speakers, please omit those steps pertaining to such. Step 7 Use this template to mark all mounting holes and stock speaker location (if desired). Passenger side template is visible, simply turn template over to use on drivers side. Step 8 Door Speakers Using an air saw or other cutting device, cut out the speaker hole you marked in step 7. Speaker size is 6 . Step 9 Using a -inch drill bit, pre-drill the holes you marked in Step 7. Tip: You can use a socket (over your drill bit) as a depth measuring tool when pre-drilling the holes. This prevents you from drilling through the outer skin of the door.

Step 10 Line the new panel up with the door and locate the door lock rod and its location on the panel. Drill out the hole in the corresponding location on the new panel. There is some play with the lock rod so a precise location is not crucial. Once the lock rod hole is drilled, hang the panel on the door. Step 11 Mark the bottom edge of the front panel. This is where you will mount the lower panel bracket. Step 12 Attach the lower mounting bracket to the door, making sure to line up the bottom of the bracket with your guide mark from the previous step. Note: Take into consideration the thickness of material you are using and expect to make slight corrections to this bracket, either up or down, depending on your material of choice. Step 13 Using a 1 hole saw or uni-bit, drill out the previously marked holes (for door handle and door latch lever) towards the center of the door. Note: If you use a uni-bit, you will need to loosen the window track for clearance. Step 14 Using the holes you just drilled as a center point, line up the small rectangular brackets (one for each hole) and mark the two outer holes. To ensure accurate alignment, flip the bracket around and place center circle (raised) within the hole and double check your markings for the outside holes. Once marked, drill out for supplied hardware.

Step 15 With both holes drilled and their corresponding mounting locations marked and drilled, install the rectangular bracket from the inside of the door, with the protruding circular portion coming back through the hole. Using the provided hardware, attached the plate/bracket to the door. Note: Only one bracket came with your door panels and is used with the supplied pull lever. The second bracket (which is used to secure your door handle is only provided with Fesler interior door handles. If you are using your own door handle, it is your responsibility to have any and all necessary hardware required to mount them to the door and panel. Step 16

If using a door speaker (not included but available) this is the point in the installation where you would install the unit. Step 17 (optional step if Fesler door handles were purchased with panels) Temporarily mount the door handle to the bracket located near the front of the door (near speaker location). At the same time, mount the door lever pull (provided) to the remaining bracket through the hole affixed with the bearing. This bracket will sit vertical against the door with the step residing in the stock handle location.

(optional step if Fesler door handles were purchased with panels) Each kit includes two small pieces of stainless steel rod. ROD IS CUT TO FIT. Lay the rod from hole to hole between the handle and door latch lever as show. Mark the location of each hole on each end of the rod. This location will be where the rod is bent. . .NOT CUT.

Step 18 (optional step if Fesler door handles were purchased with panels)

Using pliers bend a 90-degree angle at your first mark for the door handle. To make sure the rod does not slip once installed, bend another small 90-degree angle in the opposite direction at the end of the piece you just bent. The rod end for the door latch will need to be bent into a U shape.

Step 19 (optional step if Fesler door handles were purchased with panels)

Install the S shaped rod-end into proper location on the rear of the door handle. With rod installed on handle, mount handle to door.

NOTE: IT IS STRONGLY SUGGESTED THAT YOU DO THESE STEPS HERE, WITH THE PANEL OFF, TO ENSURE THE HANDLE AND MECHANISM WORK PROPERLLY.

Step 20

Using the original door pull rod from inside the stock door, hook or loop the end of the stock rod to the step portion of the vertical door pull lever we installed previously.

Finally, attach the U shaped end of the stainless steel rod to the vertical door pull and test the assemblys operation.

Step 21

Set the front door panel on the door. Using the supplied wood spacers, align the front panel to match evenly with the already installed rear panel. Once aligned, pre drill

then mount front panel using the supplied hardware in the outer two

mounting locations.

NOTE: WHILE MINOR, SOME FIBERGLASS TRIMMING MAY BE NECESSARY FOR A PERFECT FIT.

This is the point in the installation where you will wrap the panels in the material, foam and design of your choice. There are no illustrated steps for this process. Fesler HIGHLY recommends having a professional upholstery shop do the design and upholstery install on the panels.

Step 22:

Once wrapped, install the new panels on the doors using the provided hardware.

NOTE: BE SURE TO INSTALL YOUR DOOR PANEL SLIGHTLY HIGHER THAN THE BOTTOM OF THE DOOR TO AVOID IT RUBBING ON THE DOOR SILL PLATE.

Step 23: (optional step if Fesler door handles were purchased with panels)

With the wrapped panel installed on the door it will only be necessary to re-attach the stainless steel rod to the handle itself as the other end should be attached behind the door panel. After attaching the rod to the handle, screw the handle in place.