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I removed the vinyl and foam padding so I could use the base as a template and cut out the new bases out of 1/8" thick panel board.
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Before attaching the new foam, I "test fit" them and trimmed any edges that needed it.
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I applied 3M Super 77 to one side of the panel board and the foam to ensure a good bond to the panel board.
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I laid the panel with foam attached onto the vinyl and traced an outline about 1" from the edge of the board. I used the 3M Super 77 again to attach the vinyl to the foam, applying a coat of the adhesive to both for a good bond.
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I found using Weldwood Contact Cement provided the best bond of the vinyl to the back of the panel board. I applied a coat to the board and vinyl, let them set up for a few minutes, then pulled the vinyl taught and pressed in place on the back of the board. I used some plastic door shims and clamps to hold the vinyl tight against the board for about 30 minutes to let the contact cement set. Around the curved edges I cut the vinyl so it would not overlap on the back. This was the most tedious part - one section at a time, let it dry, move on to the next...
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I did not attach the snap button to the new panels yet. The original ones are riveted to the panel. I should be able to add any in the future by screwing them in place if I need to for securing a convertible top boot.
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I purchased new panel clips from Dean. Before I complete the install of the new panels, I'm going to replace all the twisties and posts along the body in this area; they are much easier to install without the panels and the tub skirt-trim piece in the way. I'm also taking the opportunity to clean up and paint the convertible top mounting brackets and the top cable receivers.
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This little project wasn't all that difficult - just a time consuming one - but very rewarding.-jt