Thanks to the Lesley University Technical Drawing students for measuring up the hole locations from a spare BMW 2002 door. Missed a few holes, but most were right on target!

The old door card and the new panel, side by side. The new panel was cut from 3mm expanded PVC foam sheet on CNC Router. The hole locations from the students’ layout takeoff were pretty close, but some adjustments needed to be made, of course. We note the location change vectors right on the card for the next iteration.