How to make Custom Track Door Cards from Foamex, ABS Plastic or Carbon Fibre

At Race Car Door Cards, we specialise in providing high-quality lightweight door cards for a wide range of race cars, rally cars, trackday cars, classic cars etc. We offer a range different materials depending on your requirements. Foamex and ABS plastic are a cost-effective and versatile solution for those looking to customise their racing cars.

Working on racing cars has become a popular hobby among people of all ages, with many forums and videos available for those new to the field. Despite the popular belief that this hobby is expensive and difficult, there are a range of materials and techniques that are readily available to make it manageable and cost-effective.

Foamex, ABS and Carbon Fibre, are lightweight materials that are commonly used in automotive customisation projects. Many track car owners use it to replace their door cards, which not only saves weight but also gives the interior of the car a more focused feel. Additionally, it is a safer alternative to completely removing door cards as it covers the sharp interior edges of the door.

At Race Car Door Cards, we offer Foamex, ABS and Carbon Fibre as three of our five products. Whether you’re a professional mechanic or a novice car enthusiast, Foamex, ABS and Carbon Fibre are a great solution for your racing car project. Contact us for more information for your next project.

How to Install a Track Car Door Card

1. First, visit the Race Car Door Cards website and browse the selection of  door cards. Choose the size and thickness that best fits your needs.

2. Once you have selected either Foamex, ABS and Carbon Fibre, add it to your cart and proceed to checkout.

3. After placing your order, you will receive a confirmation email. Wait for the Foamex, ABS and Carbon Fibre sheet to be delivered to your address.

4. Once you have received the Foamex, ABS and Carbon Fibre, you can begin preparing it for installation. Measure and mark the sheet according to the dimensions of your door card, and then use a sharp knife or a saw to cut the sheet to size.

5. Clean the door surface and the back of the Foamex, ABS and Carbon Fibre sheet thoroughly with. Make sure the surface is dry, clean and free of any dust.

6. Apply a suitable adhesive such as contact adhesive or 3M spray adhesive to the back of the Foamex, ABS and Carbon Fibre, and carefully place it onto the door, making sure to align the edges and smooth out any bubbles or wrinkles. Or alternatively, you can use rivet nuts to attach the door card to the car. This method requires drilling holes in the door card and the Foamex, ABS and Carbon Fibre, then inserting the rivet nuts and tightening them with correct tool.

7. Allow the adhesive or the rivet nuts to dry completely, following the manufacturer’s recommended drying time.

8. Once the adhesive is dry, test the door and ensure that it opens and closes properly.

9. Finally, enjoy the new look of your race car interior and the benefits of the lightweight and cost-effective solution that Foamex, ABS and Carbon Fibre sheet provides.

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Please note that this is a basic instruction, it is important to consult with a professional or a mechanic before starting any modifications on your car. Additionally, it’s important to follow the instructions of the adhesive or the rivet nuts you use as well as the safety and handling precautions of Foamex, ABS and Carbon Fibre.

Benefits of Using Foamex, ABS for Door Cards

• Easy to cut and drill

• Extremely lightweight

• Will not be affected by moisture or damp

• Very affordable

• Can be cut with a Stanley knife, no power tools are required

• Simply nail, screw or rivet to surfaces

• Rigid and durable

• Attractive finish with a smooth surface