For those of you who don’t know, Kydex is a heat shapeable plastic sheet that comes in various thicknesses and it’s commonly used for concealed carry pistol holsters and knife sheaths. I’ve worked with it before and it’s pretty tough stuff.
Some day if I have access to a wood shop again, I’d like to make a wooden router template for all four doors of these Volvos and try making a set of Kydex inserts. The material is available in various sizes and while it’s not cheap, it would last forever and it’s very easy to work and would look nice.
The approach I would use would be to create a wooden template that would mimic the smallest flat surface profile in the door alcove from the door handle all the way back to the wide end, plate the Kydex over the template and trim it with a laminate trimmer. Then I would carefully slice away all the vynil on the door that was pulled loose and place the Kydex in there so it would pull all the remaining loose vynil tight. I’d probably attach the Kydex with spray glue and some small screws at each end that could be hidden behind a cap.
I’m sure this would work, but I just don’t have the time and resources to do it now. The idea of plywood is good, but it Kydex would probably be better as it is much thinner and weather / temperature resistant than wood.”
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