Replacing front passenger int door panel cloth

Renee209 · Post by **Renee209** » 10 Feb 2019, 18:14

I just got a 2006 Volvo s40 2.4i. The miles were low but the interior was kinda trashed. The seats I can get cleaned but on the right front door the cloth has come loose and it’s all rusted and funky beneath and falling off. I’ve attached a picture to show which area I’m referring to. Does anyone know what to do with this? I can’t find the panel for sale online I tried using some spray adhesive but it made a mess, totally didn’t work and soaked into cloth made it look wet. Pretty sure I made it worse. It’s a total eyesore- others doors are okay for the most part. Thanks! SO glad this forum is here looks awesome!

Post by **RickHaleParker** » 10 Feb 2019, 18:53

It looks like you cannot buy just the part you need new. New, you would need to buy the entire door panel for ~$400.00.

There is a 2007 S40 at Pick-n-Pull 3419 Sunrise Blvd • Rancho Cordova, CA 95742. Go get the part you need, take it to a upholstery shop and have it recovered. If your lucky the door panel in the 2007 will be in good condition and the right color, a door panel is $31.99.

There are at least three Pick-n-Pull locations in the Sacramento area. There are some 2nd generation S40 at the other locations so look around and make the best pick. Use the "Check Inventory" on the Pick-n-Pull website.

X40: 1995–2004 (1st generation)
P1: 2004–2012 (2nd generation)

Renee209 · Post by **Renee209** » 10 Feb 2019, 19:28

WOW! Thank you so much! I haven’t really looked at just pulling that fabric part of the panel off- I didn’t think of that. I found SOME passenger door panels online on eBay but they were either leather, wrong side, or just different design :/ And they were under a 100 bucks so not too bad. I’ll have to go take a look at the cloth area and see if it’s removable/replaceable? If so then I’ll check the places you listed thank you. If not I guess I’ll be back

This cloth paneling looks to be an ongoing issue with some Volvo’s. Wondering if I should just take it to the auto upholsterer and have them replace it with a different material altogether? Something that matches the interior. Idk about finding clean cloth from the pick and pull places. I have dogs too & think I might need something sturdier anyways. Few options I guess? I’ll call the upholsterer tomorrow & see what it would run doing the doors. Thanks again.

Polestar · Post by **Polestar** » 15 Mar 2019, 20:57

I replaced the cloth panels on my 2005 S40. It's quite a job. If an upholstery shop is familiar, they would most likely turn you down because of the amount of labor involved. I found, if I remember correctly, around 40 plastic rivets (fused or melted) that hold that insert to the main door panel. I carefully drilled and cut out the rivets, taking care to only take off the surface parts and not drill thru. The glue is a mess to remove, I used acetone then some xylene solvent to clean after scraping all I could. Any non smooth surface will show thru later when it is covered. So after it dried, I used some heavy grit sandpaper to smooth it all down. Anyway, I purchased some upholstery fabric at JoAnns and had a shop do the covering. They said they would refuse those panels as a complete job because the labor would be so high. For the re assembly, I used a combination of a plastic welder with a hot glue gun. I found the hot glue held the best on that plastic after trying several epoxies. The problem is, I imagine that panel was put together on a jig by a machine, and it is impossible to get the tight tolerances and fitment after taking it apart. I used lots of wood working clamps. A thicker fabric can help cover the edges. It's a big job. I see you posted this a while back and probably had it finished by now, maybe this can help someone else. Good luck with it.