We are absolutely loving our Thor Tellaro, but the attention to detail and fit and finish on many things is just not where I think it should be.
Today we tackled the sliding door panel separating issue. I wish I took before pictures but I am sure most of you know what I am talking about.
Thor screwed in fasteners at 3 locations, the remaining were automotive plug style lugs that they attempted to glue to the rear of the panel and connect to the corresponding holes in the door. The problem is this glue doesn’t hold and the panel pops away from the fastener attached to the door.
Today I removed the panel and all of the plastic plugs from the door. I then put the plugs in a vise and carefully drilled a small hole in the center of them.
I then drilled from the rear of the panel through the cardboard and foam until the drill bit touched the vinyl cover, being careful not to go all the way through. Each location you need to drill is marked with a little white dot. I guess this is so Thor knows where to glue the plastic fasteners.
I then took a small needle and pushed it from the rear through the hole I drilled and the vinyl and marked its location with a sharpie.
With the locations marked I used Dura Snap Upholstery buttons and screwed through the panel into the fasteners that I pre-drilled. I held onto the fastener with some leather work gloves and tightened them in place.
Once I had attached them all it was pretty simple to line it back up on the door and attach it.
Mine was warped so bad the insulation was falling out and the panel would get wet and dirty from the outside of the van whenever the door opened.
The finished panel looks great, all though the color of the upholstery buttons I bought was slightly off.
Great job!! 
Linear Mode
