Im not sure that it is manufactured in the way that you imagine, so I'll describe what youll find: and hopefully this will help. The door cards are made out of fibrelite (which is somewhat like a wet moulded hardboard) and are covered in a thin layer of padding (like the filling from an anorak, if youre old enough to remember?). The trim material is then (very lightly) glued to this interface material, which in turn is lightly glued to the fibreboard. The vinyl door cap is added last and it is secured by gluing the top and sides where they overlap the edges and by heat welding along the horizontal joint. There are two welds and the ridges will be quite clear if you look closely.
When I ststed that it was quite difficult and time consuming, I meant that it is not a simple to job to remove the vinyl cap from the rest of the door card. The cap isnt a seperate part, its glued and bonded to the one piece of composite board and the weld is impossible to undo without damaging the part. That said, you dont want to undo the weld, because this is needed to keep the part looking finished and presentable.
When you have the door card off I would suggest that you cut the bottom section off and discard it: I used a jigsaw and left about an inch of material below the weld. This is where it gets difficult and time consuming..... You now need to trim along the weld using a very sharp sturdy knife and a very steady hand and the longer you take, the better a result you will obtain. I did mine twice, as I was able to get a better finish by trimming up to the higher weld, but Id suggest that you aim for the lower weld because this way youll still have a second chance. With patience you will be able to cut through the fibre board beneath the vinyl, along with the material (that the vinyl is welded onto) and the interface material underneath that. I waas able to obtain a better finish by concentrating on cutting the vinyl neatly and then cutting the board into its new position using a new cheap woodchisel vertically. Then all youll have to do is feather the back of the cut to help the capping to sit well over the new doorcard that you fit...
]). Anyone made some RS-style replacements? Found these on another forum and look like just what I'm after. Has to be pretty straight forward - looks like the top part is OE and the bottom has been replaced/retrimmed. My question is, has anybody tried separating the 2 parts? Mine seem pretty much glued together without taking them off to see? Cheers. 
