S4 door inner skin holes

Elan Discussions
1

With thanks to the original poster of this picture, could anyone confirm that the holes in the inner skin of this S4 door are original?

I have just removed my doors and they are in dreadful shape. They have been badly hacked about, I assume to fit speakers. Its going to be a major reconstruction job to get them back into some sort of decent order.

Thanks in advance for any feedback.

door
door999×750 196 KB

Edit: To give you an idea of what I am up against, picture below of my inner door skin. It looks like a good part of the restoration is going to be repairing the bodges of POs.

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2

The upper picture does show the correct inner door skin re: holes.

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3

As per @gjz30075, that appears correct. The interior of my S4 FHC is currently apart, so I snapped this picture for confirmation. Let me know if you need any measurements.

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-John

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4

Thanks John and gjz for the replies.

John - if you get a chance to measure the diameter of the the round hole at the bottom left of the door near the footwell, that would be very helpful.

Andy.

5

What I find interesting about these holes, is that they are obviously (to me) for loudspeakers. What other reason might there be for their existence?

6

Access to the lower hinge and allows room for your hand to get in there to help route the window motor wires.

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7

Left to right they are for:-
Access to the bottom hinge.
To fit, fix and connect the motor.
:- Top right is to access the screws and nuts for the door lock.
The window cable and pulleys have already been assembled on the inside of the window frame before the frame is lowered into place.
Eric in Burnley
1967 S3SE DHC

8

Andy8421, the hole is 3-7/8".

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9

John,

Thanks for this. Now to figure out how to repair the damage.

Andy.

10

You could probably use your other door to make a mould, the tricky bit will be recessed part that the nut to hold the frame sits in, the rest is just flat panel that need the right size holes cutting out. As it’s right to left you will need to invert it but as it is symmetrical it should be ok. Make sure you use plenty or release agent or use a polythene mask, the latter will leave you with wrinkles but you could file and fill to make a good mould which would allow you to make the actual repair panel.

I used this method for parts on my car and they turned out really well.

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