Paint & Body Work - The FAMOUS Door Panel Cracks

Has Anyone figured out how to fix this problem? And if so, could you post pics? Why does it happen on so many Firebirds and Trans Ams?
Thanks

I would assume they are just made out of shitty plastic..lol. Mine has a small crack in the driver's side door at the top...would like to stop it before it gets bigger.

Also, http://ls1tech.com/forums/pontiac-firebird-1967-2002/440767-cracked-interior-door-panel-dont-quote-pics.html

I've just learned to accept it. lol

I used a 2 part epoxy for plastic and reinforced mine from the backside with a thick/durable piece of plastic epoxied to the door panel. I heated the reinforcement plastic and shaped it to match the door then epoxied it to the door panel. I had some large clamps and an aersol can fit the inside contour of the door panel very well to hold it all together while the epoxy cured. Has held up great for the last 4 years that way. Crack has not spread and I have had the door panel off this spring to replace the window motor and everything was still holding tight. The crack is hardly noticeable.

Here is what mine looks like now after doing the stated previous work 4 years ago. No, it is not perfect, but I have thought about covering them now in leather or a similar material.

Wow, the flash made the fading on top look worse than it does with the naked eye..lol

Driver's side
http://i41.tinypic.com/15cdn9w.jpg

Pass. Side
http://i44.tinypic.com/htd4l1.jpg

Looking good...
I'm gonna have to give that a try :)
Hopefully mine will look as good as yours, because those cracks bother me so much!

It is from the preload that putting the window all the way down causes. Watch the door panel next time you roll the window all the way down to the stop. Crappy design. I am going to have to tackle this after I finish the repaint, new top, turbo kit, probably never.

I never put my window all the way down, maybe that is why my "fix" has held up for so long. I usually stop my window when it is even or just a hair above the window sweep.

Here is a good take on it as well

http://ls1tech.com/forums/appearance-detailing/1325462-how-fix-your-already-cracked-door-panels.html

Last week my window fell in lol. After getting a new felt stabilizer thing that is what causes the cracks. The window is so big and the motor is so powerful that it pulls those stabilizers beyond their bolt holes and it flexes the metal where they are attached at. That is why the panels are all cracked. GM fail of a design on that part. The whole window setup is stupid in general. I would guess putting foam or some sort of padding over the felt stabilizers might somewhat help.

High Performance Pontiac believes there are too many staples on the inside of the panel and that causes pressure on the panel which eventually cracks it. Pull out the back 3 or 4 staples and replace them with bolts.

I find it odd how I have never seen this on an LT1 car, but like every other LS1 car has it...along with peeling clearcoat on the sail panel and cracked dash covers...

I find it odd how I have never seen this on an LT1 car, but like every other LS1 car has it...along with peeling clearcoat on the sail panel and cracked dash covers...

It's a design/manufacturing issue. To relate it at all between the engine used is a fallacy. The Camaro/Firebird V6/1LE Formula panels do not crack. It is only the TA panels that crack. Also, I have seen whole LT1s with peeling clear coat and cracked dash covers and interior panels. They are not immune/better.

I pulled the last few staples on my door trim, epoxied the crack because It pulled itself back together, and used very thin wire to replace the staples.

Looks great and didn't cost but like 5 bucks for the epoxy

It's a design/manufacturing issue. To relate it at all between the engine used is a fallacy. The Camaro/Firebird V6/1LE Formula panels do not crack. It is only the TA panels that crack. Also, I have seen whole LT1s with peeling clear coat and cracked dash covers and interior panels. They are not immune/better.

Well yeah, the clearcoat can peal on anything. The LS1 cars do have major issues with the clear coat on the sail panels though, even GM admitted it and had a recall I believe. My buddy's '00 SS had peeling clear coat at 11,000 miles on a car thats been garaged it's entire life. How are the TA interior panels any different from base firebirds? Mine look exactly like every other 4th gen firebird Ive ever seen...

Well yeah, the clearcoat can peal on anything. The LS1 cars do have major issues with the clear coat on the sail panels though, even GM admitted it and had a recall I believe. My buddy's '00 SS had peeling clear coat at 11,000 miles on a car thats been garaged it's entire life. How are the TA interior panels any different from base firebirds? Mine look exactly like every other 4th gen firebird Ive ever seen...

First off, it's not a clearcoat issue. It has been thoroughly documented on this site as an issue with the adhesive used to attach the sail panels when GM made a change in the glue choice sometime around 1998. The glue turns into a liquid and eats through the SMC/fiberglass. There was no recall placed, only a TSB, and some people fought like hell to get their cars fixed for free/cheap since it was only a TSB. The only solution is to replace the entire roof skin and use a non-aggressive adhesive like windshield adhesive.

TA's were only available with the Monsoon speaker system, which has tweeters. The base model Firebirds have only a four speaker system, with no tweeters. Therefore GM made separate door panels that did not have tweeter pods (otherwise people would contact GM and be like "wtf, why isn't my tweeter working?") for the base models with 4 speaker sound systems. I have also seen those same door panels also used on 1LE Formulas. The V6/1LE panels do not have an issue with cracking as the TA panels do.

First off, it's not a clearcoat issue. It has been thoroughly documented on this site as an issue with the adhesive used to attach the sail panels when GM made a change in the glue choice sometime around 1998. The glue turns into a liquid and eats through the SMC/fiberglass. There was no recall placed, only a TSB, and some people fought like hell to get their cars fixed for free/cheap since it was only a TSB. The only solution is to replace the entire roof skin and use a non-aggressive adhesive like windshield adhesive.

TA's were only available with the Monsoon speaker system, which has tweeters. The base model Firebirds have only a four speaker system, with no tweeters. Therefore GM made separate door panels that did not have tweeter pods (otherwise people would contact GM and be like "wtf, why isn't my tweeter working?") for the base models with 4 speaker sound systems. I have also seen those same door panels also used on 1LE Formulas. The V6/1LE panels do not have an issue with cracking as the TA panels do.
My 2000 v6 firebird has the Monsoon speaker system and cracked door panels. I think the only difference between firebird and trans am door panels is the leather inserts on panels.

My 2000 v6 firebird has the Monsoon speaker system and cracked door panels. I think the only difference between firebird and trans am door panels is the leather inserts on panels.

Re-read what I typed. BASE MODEL Firebirds have the base speaker system, not the Monsoon system. The Monsoon system was an OPTION and therefore it did not come on BASE models.

First off, it's not a clearcoat issue. It has been thoroughly documented on this site as an issue with the adhesive used to attach the sail panels when GM made a change in the glue choice sometime around 1998.

Correct.

This is absolutely NOT a clear coat issue. There is a thread sticky at the top of this section that explains everything in excessive detail.

The change appears to have been made in May of 1998. 4th gens built in or after 05/98 are subject to the condition. There is no official GM confirmation on that, as they issued the TSB for *only* '99-'02 cars, but it seems that the change was actually phased in a bit eariler than GM Corporate may have realized. Those of us that have investigated this over the years have discovered several examples of cars built in May '98 or later that also have the condition, just like the '99+ cars. I don't have enough data on April '98 cars to say for sure whether or not they are affected, but after 9 years of research I've never seen a 4th gen built in 03/98 or earlier ever have this problem. All 4th gens built in or after 05/98 through the end of '02 production are definitely at risk though.

Just an FYI.

FWIW my 98 was made in June, stored outdoors all the time, and it never had a spot of trouble with the sail panel. I may have just lucked out and they had enough of the old glue left.

No sign of any problems on my current 99 yet but I suspect it is only a matter of time :(

FWIW my 98 was made in June, stored outdoors all the time, and it never had a spot of trouble with the sail panel. I may have just lucked out and they had enough of the old glue left.

No sign of any problems on my current 99 yet but I suspect it is only a matter of time :(


I think color pays a role in it too. The lighter the color, the less bubbles. I have to look very hard to see the approx 10 bubbles (total) I have on mine.

TA's were only available with the Monsoon speaker system, which has tweeters. The base model Firebirds have only a four speaker system, with no tweeters. Therefore GM made separate door panels that did not have tweeter pods (otherwise people would contact GM and be like "wtf, why isn't my tweeter working?") for the base models with 4 speaker sound systems. I have also seen those same door panels also used on 1LE Formulas. The V6/1LE panels do not have an issue with cracking as the TA panels do.

My Y87 v6 Firebird had the base 4 speaker system, but had tweeters. I do not recall ALL of the benefits of the Y87 package but I don't recall the speaker package being an improvement. Am I wrong?

I had zero cracking issues with the door panels I will say though :usa:

My point remains the same. My '95 has just over 100k miles along with the 10 speaker system and I haven't had a single problem with my interior panels. My buddy's '94 TA is approaching 150k miles and has never seen a garage, has been ripped apart about a thousand times, and still has no interior plastics problems. Yet it seems to me every other LS1 TA i see, including low mileage/garaged ones have cracks in the door panels. Sorry if that offends anybody.

My 2000 v6 firebird has the Monsoon speaker system and cracked door panels. I think the only difference between firebird and trans am door panels is the leather inserts on panels.

My 94TA and my 95 Firebird did not have cracked panels.

My 99 TA is ok so far but my 2001 Firebird panels are both cracked,BTW my 01 has the Monsoon system.

JB weld works on it and you can get the color close when you mix it.

I have also never seen an LT1 T/A that has this problem. Maybe different plastic was used?

Mine is a 97 (and so has the newer interior) with the Monsoon option, no problems after 15 years, and I've had a few LT1 T/A owner friends (also with Monsoon) that are even older, also with no problems. I've seen LT1 T/As in junkyards with no problems. There is definitely something to it.

So maybe the 'permanent' solution is just buying older T/A door panels from eBay?

I was begining to wonder if I was the only one lol. I mean I have seen some really rough and neglected LT1 cars that don't have interior cracks, and have seen some meticulously cared for/garaged low mileage LS1 car with cracks a few inches long on each door. Weird.

My Y87 v6 Firebird had the base 4 speaker system, but had tweeters. I do not recall ALL of the benefits of the Y87 package but I don't recall the speaker package being an improvement. Am I wrong?

I had zero cracking issues with the door panels I will say though :usa:

Not possible to have the base speaker system and the tweeter/Monsoon panels. Tweeters count as additional speakers, so your car has a 6 speaker system... Which isn't the base 4 speaker system (math fail). I'm willing to bet you mysteriously have a Monsoon amp in your car too, or the tweeters aren't hooked up with factory wiring.

I have also never seen an LT1 T/A that has this problem. Maybe different plastic was used?
Yep. There were I believe 4 to 5 (or more) different shades of gray used for 4th gen interiors. I guess it's possible that they changed additives in the plastic after a certain year. I notice the cracks mostly on Ebony 00-02 panels. I wonder if there is any difference in material thickness between years? (doubtful...)


So maybe the 'permanent' solution is just buying older T/A door panels from eBay?
It's only a solution if you don't mind mismatching colors, or leather wrapping your entire interior.

Not possible to have the base speaker system and the tweeter/Monsoon panels. Tweeters count as additional speakers, so your car has a 6 speaker system... Which isn't the base 4 speaker system (math fail). I'm willing to bet you mysteriously have a Monsoon amp in your car too, or the tweeters aren't hooked up with factory wiring.


You lost the bet, there is no Monsoon amp in my car. Didn't even think about the tweeters counting as speakers. Not sure if the tweeters are hooked up to the factory wiring, kinda hard for me to tell and I haven't really dicked with the speaker system all that much, though my fronts blew out so it might be time to start looking into that. I also discovered when I dynamatted my interior that I have no sail panel speakers, so who knows how much I've been missing out on.

You lost the bet, there is no Monsoon amp in my car. Didn't even think about the tweeters counting as speakers. Not sure if the tweeters are hooked up to the factory wiring, kinda hard for me to tell and I haven't really dicked with the speaker system all that much, though my fronts blew out so it might be time to start looking into that. I also discovered when I dynamatted my interior that I have no sail panel speakers, so who knows how much I've been missing out on.

Please exit the conversation.

I used the repair that 97RAMSST posted for my passenger side door cover. Worked great, as you can barely see the crack if you are looking for it. I went ahead and did my DS even though it hadn't cracked yet.

Please exit the conversation.

You are just mad that you lost the bet. Let's take a walk over into the Automatic Transmissions section and have us a chat there then hmm? ;)

You are just mad that you lost the bet. Let's take a walk over into the Automatic Transmissions section and have us a chat there then hmm? ;)

What bet? You said you have tweeters, I said are you sure they are factory and hooked up, and you said you had no clue and aren't knowledgeable on the subject, later mentioning you just realized you don't have hatch speakers... Are you sure you don't have a Monsoon system and wires to hook up factory hatch speakers? You weren't too sure about even having working tweeters. And yes, this is relevant.

You also have an Ebony swapped interior. Which means you have different door panels from stock.

What bet? You said you have tweeters, I said are you sure they are factory and hooked up, and you said you had no clue and aren't knowledgeable on the subject, later mentioning you just realized you don't have hatch speakers... Are you sure you don't have a Monsoon system and wires to hook up factory hatch speakers? You weren't too sure about even having working tweeters. And yes, this is relevant.

You also have an Ebony swapped interior. Which means you have different door panels from stock.

"I'm willing to bet you mysteriously have a Monsoon amp in your car too" - ZexGX

That bet.

They were factory, they were on my stock door panels as well. I didn't just realize I don't have hatch speakers. I do have hatch speakers, I don't have sail panel speakers, and I learned this back in December.

I'm confused to be honest, I'm just wanting to know exactly what speaker package my car came with.

Here's the lowdown. I bought the car bone stock as you already know, I thought it had the door speakers, tweeters, sail speakers and hatch speakers. It turned out I never had sail panel speakers and I do not know if I have tweeters or not, but if I *HAD* to guess, I would say I do, but I'm not positive. I feel like I recall disconnecting wires to them from previous door panel removals, but I could just be speaking out my ass here. I've had my interior apart several times now and can safely say there is no Monsoon Amp in my car, so does this not mean I have the the base speaker package, even though I had tweeter provisions in the door panel? It throws me off :bomb:

I've had my interior apart several times now and can safely say there is no Monsoon Amp in my car, so does this not mean I have the the base speaker package, even though I had tweeter provisions in the door panel? It throws me off :bomb:

Dude, every 4th gen with a sound system from the factory had sail panel speakers. Your shit has clearly been tampered with if it is missing the sail panel speakers. You cannot get hatch speakers (and tweeters) on a 98-02 Bird without the Monsoon option.

Dude, every 4th gen with a sound system from the factory had sail panel speakers. Your shit has clearly been tampered with if it is missing the sail panel speakers. You cannot get hatch speakers (and tweeters) on a 98-02 Bird without the Monsoon option.

Interesting. So I had no Amp or sail panel speakers, so I likely had the Monsoon package, but that shit was tampered with. Interesting indeed.

Weird part was, person who owned it before me was an Indian dude who owned it for about two months, and the person before that was an old lady, and when I removed those panels for the first time it seemed like they never were removed before, like, EVER. Maybe I just got a factory dud?