89 Chevy Crew Cab Door Panels

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PostPosted: Tue Mar 09, 2021 8:56 pm
This thread is a little out of this forum's regular wheelhouse but it is "auto" related and I figure that someone might get something out of it as the Chevy Squarebody trucks are getting kind of popular.

I am in the middle of redoing the interior of my 89 Crew Cab, adding the missing headliner and doing a stereo install.
I bought the truck from back East and had it dragged out to Northern California knowing that the previous owner had pretty much Micky Moused the build - I just didn't realize how bad it was until I started spending some quality time with the truck. The PW/PLs dont really work. One fuel pump didn't work which is actually good as the pump was wired with 24 ga wire directly and through a wayyyyyy tooo small switch. I am suprised that it did not catch on fire, they just melted in my driveway!!!!

This is what I started with on the interior door panels, a poorly executed SEM rattle can all black hack job. BTW the headliner and trim pieces showed up missing along with no rear seat floor brackets.

89 Door Interior (1).jpg

89 Door Interior (2).jpg

89 Door Interior (4).jpg
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PostPosted: Tue Mar 09, 2021 9:00 pm
I started by pulling the interior door panels out of a 91 parts Suburban that I have. Since Suburbans have a better chance of being in good shape, this is what I started with.

I don’t like the factory pouches and I wanted the Crew Cab interior trim rather than the Suburban trim which is different.

I also will be ditching the factory pull straps that are always broken as GM never seemed to figure out or care that folks would actually pull on them.

Along with the updates, I will be ditching the rear ash trays - Sorry, no smoking in my ride.


91 Burb Door Fix (1).jpg
91 Burb Door Fix (8).jpg

91 Burb Door Fix (3).jpg
91 Burb Door Fix (16).jpg
91 Burb Door Fix (18).jpg
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PostPosted: Tue Mar 09, 2021 9:04 pm
Stripped the panels bare and gave them a good cleaning with scuffing paste or as we call around my house "Whitewall Cleaner"

Filled the holes using a flexible epoxy with fiberglass chopped mat, added a few coats of bumper filler to prep for primer.

91 Burb Door Fix (22).jpg
91 Burb Door Fix (24).jpg
91 Burb Door Fix (26).jpg
91 Burb Door Fix (25).jpg
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PostPosted: Tue Mar 09, 2021 9:07 pm
PPG Epoxy Primer...

91 Burb Door Fix (30).jpg
91 Burb Door Fix (27).jpg
91 Burb Door Fix (28).jpg
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PostPosted: Tue Mar 09, 2021 9:13 pm
Then using a trick learned from this forum, I textured and colored the panels. Used Upol Raptor liner and a 2.2 tip, no thinning.

I really like the texture as it gives it a more modern look without looking out of place.

91 Burb Door Fix (34).jpg
91 Burb Door Fix (32).jpg
91 Burb Door Fix (33).jpg
91 Burb Door Fix (31).jpg
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PostPosted: Tue Mar 09, 2021 9:15 pm
Pulled the headliner trim out of the donor Suburban, bought a couple of missing aftermarket trim pieces that ended up fitting quite well and gave them all the same treatment.

Headliner Trim.jpg
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PostPosted: Tue Mar 09, 2021 9:19 pm
The 89 Crew Cab didn't show up with a headliner, the donor Suburban's headliner board was shot and too short (GM???), so I stole the perfectly good headliner out of an 83 Crew Cab (low geared manual) that I will be selling after I finish the interior and did this.

That is 16oz. 100% wool.

Headliner Wool (1).jpeg
Headliner Wool (2).jpeg
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PostPosted: Tue Mar 09, 2021 9:22 pm
Got my door grab pads in one color. I used three of the donor Suburban and one from the 83 Crew Cab that I am also redoing, then selling off.

I may cover them in leather at a later date.

I didn't get any photos of them in the black epoxy primer.

Door Pads (1).jpg
Door Inserts (4).jpg
Door Inserts (6).jpg
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PostPosted: Tue Mar 09, 2021 9:26 pm
I really don't like the factory pull straps as they ALWAYS break.

So, I made some door panel inserts to convert the Suburban style inserts to the Crew Cab style.

Preped, epoxy primered, base coated and cleared.

I used a high gloss clear instead of the matte clear that I was going to use. I really liked the color when I applied the base coat then decided to use the high gloss clear as I can always apply the matte clear over the gloss later if I change my mind.

I did an extra test piece and will cover it with a matte clear to help me decide which finish that I want. But right now I am leaning towards the gloss.

Door Inserts (5).jpg
Door Inserts (3).jpg
Door Inserts (8).jpg
Door Inserts (10).jpg
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PostPosted: Tue Mar 09, 2021 9:29 pm
I like the gloss so far.

91 Burb Door Fix (4).jpg
Door Panel - Plaid (2).jpg
89 Door Interior (1).jpg
Door Panel - Plaid (1).jpg
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