Suppose I should have replied again to this post once I had finally Finished those door Trims. Couldn't believe how simple it actually was. I used Black Suede for the Dash, Doors, Kick panels, Metal Trim parts on the B-Pillars, Wheel Arches and Parcel Shelf. With Green Suede Stitched on to give it some Highlights.
Anyway, thought I would show you what I came up with as a finished product.
1. I used the original trim panels (without the Vinyl covering) to copy the shape of the door onto a new piece of Masonite (approx 3.6mm). Apparently there is a reason that MDF isn't used, but I am not sure why. heard it off some motor trimmer.
2. Mark all the holes and Cut out shape with a Jigsaw, Use a 10mm Drill for the door clip holes, and I used a 38mm Hole saw for the Winder and Handle holes. Simple.
3. Use about 5mm light foam, from any Furniture Upholstery place (not Clark Rubber, Too Expensive!, Get your Suede or Vinyl from them too) and glue down onto the board. (A really
really light coating of PVA seemed to work really well, too much and it soaked into the foam and made it hard and gave the foam low spots) wait till it dries completely. Then use a Razor and cut the foam away from the top of the panel to sit in the door channel, and around the holes of the window winders. Might need to cut in slightly so when the handles are put on, it doesn't hit the Suede.
Cut any excess Foam from around the Outside of the panel.
5. I found that Quik Grip worked the best for this next bit. Not so much with the previous step as it had a tendency to shrink (not sure why). Apply a thin layer of quick grip on the foam and on the back of your Suede, leave it for about 5 mins, so it goes tacky but still workable, then its just like gluing two bits of paper together. Lie it flat and make sure it is on straight, you don't get many chances at this. Roll out any air bubbles.
6. After it dries, flip it over and use your razor to cut enough of the suede to cover approximately 15mm onto the back of the board after it is folded over onto the back. It should lie in-between the holes for the door clips. Then just do the same thing, glue both the Suede and the Door, wait till tacky, then glue it down, pulling it tight as you go to eliminate creases and make it look smooth!
7. Cut a + in the holes for the door handle and window winder and same deal again.
Seriously not that hard. But if you have a better way, then please share it. Turned out alright for a first timer! Had to make the Dash board too, Mine didn't have even the frame, It had Carpet Covering it!