Id just make new ones outa masonite....but then i dont get the neat texture, teh ribs and the varing height that makes the panel nice, ya know....i could so just the flat panel, but i unno...the stiffening method sounds good, but unfortunatly the door panels are the wrong color anyway, so repairing them isnt much or an option...though the suggestions are awsome, ive got GT panels in my 242, and i want to save em, to prevent rotting the door holes will be coverd with plastic, as the factory did, but a little better obviously. And you you know how bad an aluminum panel will vibrate and rattle!? OMG, ya i said it OMG.
I could prolly make teh template though and glue extra layers in certain places to give the panel more depth...to try to match the original ones better