2fpower
SILVER Star
let me start this with, Hi, My name is Kelly, and I am an FJ addict.
I have looked and listened, and added a few comments here and there, but this is my first thread that I have started with a project idea that I did not copy from another posting. Someone may have done this, but I did not find it online. So, this is my original twist on an common project. It all started with a desire to have half doors. The PO had purchased from Ebay a nice straight set of relatively rust free early 70’s doors. They were primed on front, and looked really nice. Knowing that there was not going to be windows, I felt like there was a lot of wasted space inside the door panel. I also know myself enough to know that I really could use some extra space to put papers, pens, etc. So, I thought that I would make some inserts for the doors. The second issue became apparent when I found a good 3/8 of bondo on the doors under the primer – yes primer hides all sorts of sins. Both of my doors have a concave nature to them. So, I needed some way to give them some more structure. My final issue with many of the half doors that I have seen on MUD is that with all of the different bends in the original inside doors skins, when you just put a new cap on the top of the door, it looked messy and you could not of imagined it coming off the factory line like that.
My issue with the inserts was how could I protect them from rust. I looked through a junkyard, and could not find anything close to what I wanted. I could make them from metal, but I didn’t think I could paint them completely if I made a pocket 8” deep, and still be able to weld them on. (I don’t want phantom rattles) One day I was looking at my shelf and I saw an stack of old stainless steel paper towel dispensers – the kind from commercial restrooms that were stocked with 3”x 10” folded towels. I thought that if the frame were narrower, they would be perfect…. Stainless steel, no need to paint them, and rust will not be an issue. Now, before you say this is way too difficult, or “you have to be an awesome welder” – the way this goes together, all the welds on the paper towel dispenser are not visable when you are done, so they can be as ugly as possible. Also, when completed the “viewable” section of the dispenser is actually the inside of the cover (hinged piece that you typically would have seen the outside of when looking at it hanging on the wall) As you can imagine, this would not of got any abuse, and all of mine were in excellent condition with no scratches. Also, the depth does not need to be precise, because this cover overlaps the stainless frame. This gives you a good ½ of movement. I did not weld these pieces together until my final fit, so I could give some pressure (structure) to my door to keep the outside straighter.
I kind of skipped ahead there, so let me back up. With nothing to loose, I marked one of the towel holders with some estimated cut lines, cut them with a cutoff wheel,
banged on them for a while to make the bends, then welded them up. Honestly, they look ugly, but again, these will not be visable.
I have looked and listened, and added a few comments here and there, but this is my first thread that I have started with a project idea that I did not copy from another posting. Someone may have done this, but I did not find it online. So, this is my original twist on an common project. It all started with a desire to have half doors. The PO had purchased from Ebay a nice straight set of relatively rust free early 70’s doors. They were primed on front, and looked really nice. Knowing that there was not going to be windows, I felt like there was a lot of wasted space inside the door panel. I also know myself enough to know that I really could use some extra space to put papers, pens, etc. So, I thought that I would make some inserts for the doors. The second issue became apparent when I found a good 3/8 of bondo on the doors under the primer – yes primer hides all sorts of sins. Both of my doors have a concave nature to them. So, I needed some way to give them some more structure. My final issue with many of the half doors that I have seen on MUD is that with all of the different bends in the original inside doors skins, when you just put a new cap on the top of the door, it looked messy and you could not of imagined it coming off the factory line like that.
My issue with the inserts was how could I protect them from rust. I looked through a junkyard, and could not find anything close to what I wanted. I could make them from metal, but I didn’t think I could paint them completely if I made a pocket 8” deep, and still be able to weld them on. (I don’t want phantom rattles) One day I was looking at my shelf and I saw an stack of old stainless steel paper towel dispensers – the kind from commercial restrooms that were stocked with 3”x 10” folded towels. I thought that if the frame were narrower, they would be perfect…. Stainless steel, no need to paint them, and rust will not be an issue. Now, before you say this is way too difficult, or “you have to be an awesome welder” – the way this goes together, all the welds on the paper towel dispenser are not visable when you are done, so they can be as ugly as possible. Also, when completed the “viewable” section of the dispenser is actually the inside of the cover (hinged piece that you typically would have seen the outside of when looking at it hanging on the wall) As you can imagine, this would not of got any abuse, and all of mine were in excellent condition with no scratches. Also, the depth does not need to be precise, because this cover overlaps the stainless frame. This gives you a good ½ of movement. I did not weld these pieces together until my final fit, so I could give some pressure (structure) to my door to keep the outside straighter.
I kind of skipped ahead there, so let me back up. With nothing to loose, I marked one of the towel holders with some estimated cut lines, cut them with a cutoff wheel,
banged on them for a while to make the bends, then welded them up. Honestly, they look ugly, but again, these will not be visable.
There is a set sitting in the garage just waiting to be carved up. 
Here's to you and your imagination!
