My ghetto fab half doors

[zjguy721]

Here is my attempt at a set of half doors. I like the position of the top rail for an arm rest (I'm kind of tall), so just sawzalled the middle out, cut off the glass frame and mirror, voila! I'm still going to paint them flat black, trim the cut edges with door edging, and replace the window rub strips on the top "rail" for cushion. A little flexy, but it's what I was looking for. Now, onto driver's side...........

[cashflowdub]

you gonna put some sheet metal in there ?????

[DJJordache]

you gonna put some sheet metal in there ?????

FOOK that, cover the hole with plexiglass would be sweet!

[H3RESQ]

I hope to god those are a joke!

EDIT: decided I needed to explain myself.

They are unsafe, the point of a halfdoor is to get better visablity while still getting some protection. Your door actually create's more danger. You have found a way to make a rather small are(a door) have an extremely large are of unprotected sharp edge's. you've also taken out all of it's ability to absorb a impact. If something makes it through the gapping hole it will hurt you, if it hits any part of the door it will hit you and the door is sure to also injure you with it's sharp edge's(even if you put fender/door trim on it once there's a impact it will bow and come off about the time it hit's your bare arm.) etc,etc,

[ATL ZJ]

I think it's a great idea. You need to fill the hole with Lexan to keep the visibility but still have some protection. It's amazingly tough. I nailed a rock with one of my skins. No damage to the lexan, but it bent the .120 wall DOM behind it.

Home Depot and Lowes both carry it. Make sure you get the most expensive kind- the other stuff is brittle and a waste of money.

[H3RESQ]

I hate to start an argument but......There's a big diffrence between bolting Lexan to a tube with welded mount brackets and mounting lexan to sheetmetal.(that's all that's left at the top of his door.)

Don't get me wrong with some tube work added it would be a diffrent story, but he's yet to mention any thoughts of that. I stick with my opinion unless he decide's to reinforce the doors.

Keep in mind there's also a big diff between hitting a large area of lexan and hitting lexan that's sitting right on tubing. (when you hit the lexan it wasn't in a bare spot, you had to have hit directly against where the tubing was behind it.

[2jeepsforus]

First and foremost, I have no idea on the strength issue, with that stated.

I think it looks good and has a good premise. Although I must agree that lexan would be a wise choice to cover the hole and re-inforcing it wouldn't hurt either. Something like an X pattern would be great with 1 1/4" O.D. boxed steel.

Dave

[CurtP]

I guess I don't get it. I'm on the same page as H3RESQ. With those doors the way they are, I think you'd be better off with no doors at all.

[BLACKZJ]

Those are half of half doors. I do like the concept of keepin the hinges and latch. Maybe you could run some sheet metal,like 20 ga.around the cutout and lose the top part,then run DOM tube across the top part to form your safety rail/armrest.

[cashflowdub]

you should just start over

[BigDaveZJ]

I guess I don't get it. I'm on the same page as H3RESQ. With those doors the way they are, I think you'd be better off with no doors at all.

Or just roll down the window???

[Alaska ZJ]

Bolt in some Plexiglass. Screw the haters. Oh and get some edge trim to cover that 12 foot razorblade you just made...

[zjguy721]

OK, to reply (I think I'll get it all in here):

I forgot to mention one big thing, these are ONLY going to be used at the sand dunes. I'll leave the original ones on for any other wheeling. I realize, and mentioned, that they are weak and flexy, and provide no protection whatsoever from lateral impact. I would never take these anywhere seriously offroading. BTW, there is a reinforcement under the upper edge, it is cut in half lenthwise, and provides MINIMAL reinforcement. I could have cut around the one large horizontal reinforcement, leaving it there, and bolting the lexan to that for support (which I considered, and was the beginning). But then I figured I would just use these for the sand, and if I ever wanted a true tube door for real wheeling, I would have them fabbed correctly.

Oh, and I did mention also that I was putting edging around all the cut edges. I'll be trying them out this week up at Silver Lake, we'll see how it goes.

[ATL ZJ]

Keep in mind there's also a big diff between hitting a large area of lexan and hitting lexan that's sitting right on tubing. (when you hit the lexan it wasn't in a bare spot, you had to have hit directly against where the tubing was behind it.

Good point.


But I've hit them more than once, haha.. They have been knocked and smacked in both supported and unsupported areas. Dragged them and pinballed them off branches, rocks, and even the ground. They keep coming back for more. The stuff is stronger than you think.

What's the big deal? The factory doors offer little structural support. If it's a safety issue, follow the lead of the 218949124 wrangler and land cruiser guys and keep your limbs inside the vehicle.

[Kraqa]

lexan is bullet proof. and flexible as fawk.

bolt it in and be done with it.