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So I purchased a set of new seat covers. The seller also included a matching set of vinyl to go on the door panels. The factory cloth was glued and stapled around the edges on the inside.
Has anybody replaced this insert? If so, how did you secure the material to the plastic? I can't get a staple to go into it. I don't have a pneumatic stapler - I'm using an electric stapler and it's not able to penetrate. Before I go buy a pneumatic stapler, have any of you guys done this install another way?
In case anybody ever needs a thread like this, you need the pneumatic. I got a harbor freight 20 gauge stapler and used 1/4 inch galvanized staples.
For getting the trim connected to the insert, the staple gun will not go through the window trim and into the plastic panel. The staples that come from the factory would probably require a special tool. I used self tapping screws and it worked perfectly.
I didn't take pictures of how I did the job, unfortunately.
I can tell you what I did though. The staples that go through the window sill and into the plastic that has the insert are very hard. Don't pry on these or you risk damaging the plastic. I took a cutoff wheel and cut the staples and then easily pried them out.
Once those are cut, you'll have about 10 or 11 plastic rivets. I just pried up on the plastic to pop the rivet.
Now the plastic insert should be free. Don't remove the existing upholstery unless it's damaged. Any imperfection will probably show, so you'll need to take care of it. I went right over my factory cloth because I did not want to risk damaging the foam underneath.
Once you have your new material on, staple it all around the edges, similar to how it is from the factory. Now, you'll need to secure the insert to the panel. I used screws. I used screws from 1/2" to 3/4" depending on where it was going in. Just be careful you don't go too deep. I kept one hand under the insert and pressed upward while I put the screws in. You will be able to feel if you're driving it too deep. As stated earlier, use self tappers (1/2") to go through the steel window trim through the insert plastic where the factory had used the heavy duty staples and you're ready to bolt it back in.
The first door panel I did took much longer than the second. Doing the second panel took under an hour. For the first one, I tried using my plastic welder to put the rivets back in. While it did work, I didn't think it was robust enough and I feared after some time it would give out and I'd have a loose panel. The screws are super tight.
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Door panel insert replacement 
