How Do I Shape Auto Door Upholstery Foam?

A nicely upholstered car door looks neat and tidy.

Reupholstering the inside of your car is a significant job that is often best left to professionals. Reupholstering the side panels of your car doors is much easier, however. Car doors can undergo a significant amount of wear and tear. Freshen up your car's interior by replacing the upholstered side panels on the door. Most car doors are only partially upholstered, requiring you to remove the door, then pull out just the section that is upholstered. Once you do this, the section to be reupholstered becomes a helpful guide for shaping a new piece of auto door upholstery foam.

Things You'll Need

• Screwdriver (if necessary to remove door panels, based on your car make and model)
• Scrub brush (optional, for removing old adhesive and foam)
• Plastic scraper (optional, for removing old adhesive and foam)
• Heavy duty scissors (for cutting the foam)
• Heavy duty adhesive spray (specified as suitable for automotive upholstery)

Instructions

1. Remove the interior panel of the car door. Removal will vary according to the type of car you have; your car's manual or a quick Internet search for "remove (car make, model, and year) car door" will give you the specifics for removing your car's panel. This will allow you to access the upholstered piece from the rear of the panel, where it is secured.

2. Remove the upholstered panel on your car door. Again, the size and position of this panel will vary according to the make and model of your car. It may be secured by clips or screws, or simply fitted tightly and needing to be removed by prying with a screwdriver. Use caution to avoid damaging the rest of the car door.

3. Peel the upholstery and foam off the upholstered panel of the car door. Depending on your type of car and how old the car is, this may be difficult or easy. The foam and upholstery may peel off or you may need to scrape it using a plastic scraper or scrub brush. Get it as clean as possible to create a clear, smooth surface for reattaching the foam and upholstery using adhesive.

4. Lay the upholstered panel on top of the foam you will be using to reupholster the panel. Trace around the panel using a pencil.

5. Cut out the traced piece, adding an extra margin of at least 1 inch all the way around the panel, to allow for wrapping. The foam can be easily cut using scissors.

6. Apply spray adhesive to the panel, working in small sections. Shape the foam by slowly wrapping it around the panel, shaping it to the contours of the panel as you go. Work in small sections to ensure the adhesive doesn't dry too quickly and the foam is adhered smoothly.

7. Adhere the margin of foam to the back of the panel, once the foam is secured to the front, using the spray adhesive.

Tips & Warnings

• Complete the reupholstering process by wrapping the foam-covered panel in fabric complementing your car's existing upholstery. Reattach the upholstered panel to the inner door panel, then reattach the entire inner door panel to the car door.

References

• Torque Cars: Upholstery for Your Car's Interior
• Upholster.com: Upholster a Door Panel