This will be a long drawn out project. Between work, 3 kids, wife and dogs my time is pretty consumed.

Got a set of doors to cut up and went to town. Step 1 of who knows is complete.

Welding in new sheet and some body work to clean everything up to follow.

I'll start the thread with a couple pics.

 

Reminds me, I need to finish mine.

 

Got the CAD together to make a template. You know Cardboard Aided Design.

 

How are you going to do your latch? Stoked for the outcome, my jeep is the same color as those doors

 

Please be detailed on the build I want to do the same and have 0 fab skills. Would you make extra templates and send me a copy?

 

The latch will be same as stock. Instead of using an exterior / interior door handle a rod/ button will be used to open the latch from the top of the door where new metal is put in.

I will be as detailed as possible. The templates I'm using are cut specific to how I cut the door. If it's something that can be duplicated I have no problem putting them out there

I'll also take measurements of my cut lines on the other door prior to making the cuts so that'll be available for reference.

 

I'm about to start this once I can get back from the junkyard this weekend. Look around on some other forums for ideas (naxj or pirates 4x4) they have some pretty cool stuff on there about half doors. Looks really clean so far though

 

Made a lil progress today. Cut out the sheet using the template I made.
I bent it to shape using a cheap harbor freight metal brake. It did it's job bending the 16ga steel no problem.
Started the stitch weld process. I forgot how long that process is. Once it's all welded up, ole trusty grinder with a flap disc will come into play.

 

Do you have any links to share? Want to start this project soon and would appreciate the links

 

Got some more work done. Got the sheet all welded in and started the body work process with a thin layer of filler to cover a few pin holes.
For the ones wonder what I'm was doing to open the door, I added a picture of my latch release button.
Going to finalize the body work/paint prep and then I'll start the other door.

 

Loving them. I'm interested to see how that latch idea is going to work, haha.

 

Thanks.

The latch release Is simple. The rod that normally released the latch was trimmed down and attached to the billet piece you see. Pressing down on it releases the door latch from the striker. It's spring loaded so it pops back up to the same position.
The billet "button" is actually a switch extension that is normally used for hydraulic/airbag switch boxes. I've built a few mini trucks and had a few laying around. They work out perfect and look cool as a door button.
I'm on the home stretch with the first door. Once I start the passenger side I'll add all the measurements and put up more pictures.
I'll get both doors 100% ready for paint and knock them out at the same time after I get them test fitted on the XJ.
I also plan on making a set of door panels rather than welding up all the interior holes. Anyone have ideas?

 

Re use the stock ones? Just cut em to fit and put some door trim on the cut edge?

 

I tried that with the only extra panel I had. It looked like **** because of a weird gap it left. I'm taking too much time into these for that haha. Thanks for your input though.

 

I am anxiously waiting the detailed build photos and write up. Especially like the way the door will open and close.