I've had some recent thoughts about how to replace the now long gone rotten door cards that were originally fitted to the Bedouin and I've got a good idea about how to incorporate some sound deadening material, but it means making up some new door cards from raw material.

Is it available to cut to measure and if so, what is it actually called? Entering "Door card material" in Google or Ebay just brings up ready moulded specific to type cards.

MDF from B&Q or Homebase? That should do it, and you can buy some fabric from Dunelm, cut it to size and staple it to the board.

Just been out to the garage and taken these photos for illustration...

I hadn't thought of MDF Jono, but it's a idea, cheers. It's just plain board I need because I'm thinking about thick sound deadening foam on the internal side of the door & thin foam with desert camo material on the cabin side. I've got sh!tloads of foam & camo material already so I'm sorted for that

You could get creative and have a stab at making some glassfibre moulds and doing something with that. I've always wanted to have a go at it myself.

That's an idea! I keep meaning to have a word with our lads in the composite structures bay to see if they could do a fibreglass bonnet so if that's a goer then who knows? Do you mean sculpted/moulded door inserts that go into the door though & do you think they would suit the utilitarian style of the Bedouin?

Bertie, was it 'Hardboard' you were thinking of? The recycled wood stuff used for standard 2cv door trims.

Yes, it's definitely hardboard you need, not MDF. This kind of stuff: http://cgi.ebay.co.uk/Nationwide-Delive ... _887wt_821
After you've cut your hardboard, go to a fabric supply shop and get some 5mm foam sheet, and some vinyl sheets in the colour of your choice, and a haberdashers' staple gun with 3mm staples. A can of spray-tack stuff will come in handy too.

As for soundproofing, I've been using Celotex/Kingspan type stuff, which is widely used in the building trade (here's the cheapest supplier I've found: http://www.aandainsulationservices.com/ ... 4wodsWPAZw )
and Brown Bread: http://cgi.ebay.co.uk/BROWN-BREAD-sound ... 291wt_1047

Brown Bread is self-adhesive. Spray-tack will hold Celotex/Kingspan in place very successfully.

Hope this helps.

Cheers for the suggestion Smiffy, it's all put me in the right direction. It is just the board I need though - as I mentioned, I've got the rest of the stuff

I'd go MDF material rather than hardboard as hardboard 'buckles' and moves in damp conditions. I think the 2cvs original door cards must have been hardboard with a special treatment as it didn't appear to move like the ordinary stuff you can get from a DIY store.
Buy a small piece and stick in the car for a couple of weeks and see how it performs.