Found a new crack.

**10-8-TA** · 02-22-2008, 11:20 AM

Just replaced the upper dash due to a crack. Finally a repair that only took 10 minutes to do. In the past 3 months I noticed a crack in the passenger side door about 2/3rds back along the plastic. I know this is a common flaw with the TA's. However, i'm beeing told that it can be repaired instead of replaced. Has anybody had any experience with this issue?

**kikaofazz** · 02-22-2008, 02:34 PM

http://www.ls1.com/forums/showthread.php?t=76192

I just did this today to my passenger side. My door panel, as you can see in the pic, was totally fucked. After some work (2.5+ Hours), it's not near as bad. Still noticeable, but one hell of an improvement. Plus, I won't have to worry about it cracking again. I'm doing the driver's side tomorrow.

Definitely do this mod if you plan on keeping your car.

**10-8-TA** · 02-23-2008, 05:01 AM

Thak you!!!!!!!!

**Kup98ss** · 02-23-2008, 06:16 AM

My driver door has one. Pisses me off. 32,000 miles and it isn't driven that hard.

**kikaofazz** · 02-23-2008, 08:29 AM

Just as an update, I just finished up with my second panel. The learning curve is really easy. Within 90 mins I had already pulled the panel, repaired, and re-installed.

Even though it wasn't cracked, the peace of mind is what matters. It's easy to tell how the staples add pressure once you actually pull the panel & look.

**Kup98ss** · 02-23-2008, 06:46 PM

Originally Posted by kikaofazz

Just as an update, I just finished up with my second panel. The learning curve is really easy. Within 90 mins I had already pulled the panel, repaired, and re-installed.

Even though it wasn't cracked, the peace of mind is what matters. It's easy to tell how the staples add pressure once you actually pull the panel & look.

Any hints on how to get the staples out. I used a dremil and it still took for ever. I gave up once I got the 4 most important ones out. The door looks like new though. I can't even see the crack unless I look for it.
Now if it will just stay like that once I put it back in the car tomorrow morning.
Looks good in the living room though.

**Tman** · 02-24-2008, 05:16 AM

Have a few questions:

1. Did you remove the interior panel with window up or down?

2. Did you just remove the staples or did you add any screws like various write-ups that are out there?

Thanks. ( oh yeah I have a crack starting on my driver door )

**02cetransam** · 02-24-2008, 05:29 AM

this is a great fix!

**Kup98ss** · 02-24-2008, 05:46 AM

Originally Posted by Tman

Have a few questions:

1. Did you remove the interior panel with window up or down?

2. Did you just remove the staples or did you add any screws like various write-ups that are out there?

Thanks. ( oh yeah I have a crack starting on my driver door )

I took it off with the window up. I don't think it matters though.

Take the staples out then add the screws. I made the holes bigger (not much bigger) than needed, that way the door could flex a bit.

Here is a hint when taking the panel off. The sliding lock (under the handle) comes off of the rail. Pull it towards you, not towards the dash board.

That is the only thing that gave me any trouble.

**Tman** · 02-24-2008, 06:04 AM

Originally Posted by Kup98ss

I took it off with the window up. I don't think it matters though.

Take the staples out then add the screws. I made the holes bigger (not much bigger) than needed, that way the door could flex a bit.

Here is a hint when taking the panel off. The sliding lock (under the handle) comes off of the rail. Pull it towards you, not towards the dash board.

That is the only thing that gave me any trouble.

Cool ! thanks.

One more thing, what type of screws/washers/nuts did you use?

**kikaofazz** · 02-24-2008, 06:54 AM

Originally Posted by Tman

Cool ! thanks.

One more thing, what type of screws/washers/nuts did you use?

Go to the hardware store & pick up #4-40 machine bolts / nuts (1/2" in length). I used #6 washers. On my non-cracked door panel, I only used 6 bolts, one in each "section." But used all 10 in the cracked panel.

It truly is a bitch to get the staples out. I took a dremel grinding wheel and cut one "leg" off of the back of each staple then used a small flat head to pry it up & out.