Anyone know the best way to repair cracked door panels? I've seen epoxy, hot melt, and other ways but looking for actual experience - in fact, even more so, looking to hear what 'didn't work' as well.

I've noticed the 2005 to 2007 are holding up better. (not sure if they changed the mold to be slightly thicker panels or have changed the chemical make-up of the plastic) Therefore, interested to hear what's been confirmed to work on the '03 to '04 panels.

 

Which areas are we talking about ? I have a 04 and the drivers panel seems kinda loose but the clips which hold them onto the sheet metal are all not that good. If there was some way to spray on some sound deadener it may help bolster its structure like some
foam insulation.

 

Interestingly enough, most of the rattles don't come from the panel unless there is a crack in it somewhere especially cracked or separated door pockets. Where most of your rattles are coming from on the door is the handle used to open the door and the square bezel around it. Grab hold of those two things while driving and see if it doesn't quieten your rattles

 

I just changed the drivers door check or door stop limiter as it was worn out and clanking while driving. Was a tough $60 DELCO bucks to spend..LOL! I ordered one for my 04 Prius and it was like 1/4 the size of the Hummer H2 HAHAH! Another thing is I bought some carpeting to lay in the door pockets..a piece of $6 remnant makes a difference. Could cover all four doors. As always as you get rid of the the noises you notice the OTHER noises which you didn't hear...its almost a battle to the end.