Half door fabrication

[mattolewis]

I have always wanted half doors for my cruiser and the price of new ones is out of my budget so I decided to make a set. I found a rusty old set of doors on Facebook marketplace and decided to give it a try.

Step one was to relocate the inner handle so it will still work after I cut down the door. Pics attached.

Stay tuned I will try to take enough pics to show all the progress. Wish me luck!

 

[45Dougal]

What's step 2 going to be?

 

[White Stripe]

Those are rusty?

 

[OPMACHINE]

Good Luck, this has been on my list for years.

 

[mattolewis]

Those are rusty?

Yes, the bottom corners are pretty rusted out. I plan to replace the rusty metal as part of the project. I wanted to do this on rusty doors in case I ruin them. I couldn’t bring myself to cut in rust free doors. lol

 

[mattolewis]

Good Luck, this has been on my list for years.

I will post pictures as I go and share the challenges to help for your future project.

 

[mattolewis]

Here is the planned cut line. I wanted to line the back up with the tub but I had to go a bit higher to maintain the door latch mechanism.

You can also see the rear corner is totally rusted away.

 

[mattolewis]

What's step 2 going to be?

Next steps:
1. I am waiting for door hinge pins to arrive to fit the door up to the body.
2. Fit up to body and make relief in door to fit around roll cage
3. Confirm tape location lines up with tub to cut top off door.
4. Cap off top of door.
5. Form a metal piece to fit the top with a friendly radius so it doubles as an arm rest. I am thinking this will be the hardest part. I haven’t decided if I am going to do a single piece or piece it together out of several pieces.
6. Weld on the metal piece to the door.
7. Clean up all the welds for a smooth transition to the existing door.
8. Fab up patch panels for rusted metal.
9. Sand blast
10. Paint
11. Mount and repeat on other side!

 

[White Stripe]

You might want to check with the bestop doors. If you cut the doors right you could add a bestop half door window.

 

[mattolewis]

You might want to check with the bestop doors. If you cut the doors right you could add a bestop half door window.

That is a great idea! I will look into it. Thanks for the feedback.