Ideas for adding padding to top of door panel for an armrest

I plan to recover my door panels with marine grade vinyl. While I had the door panels off recently, I was looking at what it would take recover them. Looks easily. I'm not content with what is easy. Instead I had the idea of adding some type of armrest padding to the top of the door panel.

I drive most often with my left elbow on top of the door panel and left hand on the steering wheel, while I hold my the seat belt back from cinching me ever tighter around the waist. The panel on this 2000 is really thin there and my elbow bones rest awkwardly on top. The top part has thin padding over a metal U shaped piece.

My question is what kind of foam should be used for this application? I'm looking for something ¼ to ½ inches thick. I suspect whatever I use will need to be dense and not very spongy. It will have to be glued to the metal piece because it can not be wrapped around it and secured from the back because of the clearance needed for the black window felt on one side, and connecting with the rest of the door panel on the other side.

Adding padding will definitely complicate how to make the vinyl look nice when it has to conform to their irregular shape that the door lock requires. I have no experience with upholstery so I might be making too much of a challenge for myself and having it look nice.

Where I like to rest my elbow.


The U shaped metal piece from underneath, at the top.

 

I would try to find some 1/8" closed cell foam. I have a sleeping pad made out of it, and it's pretty durable and would add just enough padding to make it comfortable, without too much bulk.

How you'll attach it is the real question...

 

That's a great idea, and not expensive at all.

I guess I'll have to do tests on it to see if contact cement will work without dissolving it.