I was waffling a bit on which of the door card designs was best. I decided to use the design for the door card with an interior pocket due to passenger comfort. I installed the seat to check for elbow room spacing and there isn’t much.
So, I transcribed the template onto AL 3003 - .050 and cut the door card piece out.
There’s a decent amount of curve on the inner door frame where the door card mounts due to the tilt in the window frame. Using a combination of go-kart slick and regular anvils in the English wheel, I shaped the door card for the curve.
The door pocket was then completed in Al .040 from the cardboard templates.
Next up is adding the details onto the door card.