Firebird Door Panel Crack Repair - Door Panel Pandemic
With the door panel on the bench, we thoroughly inspected the affected area from every angle, and that's when we noticed the probable cause. The window felt is adhered to a piece of strap steel, which is stapled onto the plastic door panel. It appears that if the door panel was at all flexed while the window felt was stapled into place during the assembly process, it could leave the panel somewhat twisted. A combination of the plastic door panel reacting to temperature changes and any pressure that the window exerted on the stationary felt strip in various positions was likely to further abnormally flex the panel, causing a stress crack to form at the weakest point. You can see the telltale signs of such a crack forming just to the right of the staple.
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