Half Doors Build (Really 1/3rd) no welding
 

Ok so I got a set of doors for cheap. ($40 for whole set) I decided I wanted to build a set of chopped doors. I knew going in I didn't want to do any welding since that metal is so thin and my skills are a bit novice for such a project. I had the idea to use diamond plate and was pricing it when I was given a pair of Bed rail caps for a full sized Chevy. I figured they would work and actually worked out perfect for this project.

So here are the doors
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My first decision was how low I wanted to go. I thought about keeping the frames and mirrors then decided that the easiest cut would be this
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I would have gone about an inch higher if I knew the cross bar was that close. 6 inches from the body line up would be right flush with the inner door cross bar. For me it was to late to back track So I made it work. I will try to add some actual measurements later.
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Here is a shot while i was still working on getting the cut right.
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I knew I needed to get some kind of a support run on the inside if I wanted them to have any resemblance of strength. I had some 1.5"x1.5" angle that was for garage door opener mounts. Im not really sure what it is called but it is light weight and strong for this purpose. I cut a piece to run along the inside of the door and then used some flush bolts to hold them in place. I used rivets on the rest of the doors which was easier. This did require some finessing with the hammer to get everything to line up.
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Pic of the rear door inner brace

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The 90 degree bend on the bedrail cap worked perfect for the out side. The beveled edge worked great for the inside with a little beating to make it fit flush. Getting the diamond plate to fit perfect isnt easy take some pounding but once I got it riveted in they were super strong. No doubt anyone less than 250lbs could stand on them while closed.
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Here is where it got pretty clean. I figured I could easily use the door panels for looks and use the storage space.
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Those are sweet. I love the diamond plating

I still have the finish work to do. My plan is for them to actually look decent when finished. Here are some other pics that I have so far. i will add more pictures when I get them. Its hard to stop and take pictures when all the ideas are popping in to my head and I want to hurry and try this or that lol.
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Thanks they are coming together. I can't say better than I expected because I always expect better haha. So far my cost is around $60 total (gone through quite a few cutting disks on the ole grinder haha.

Perfect time to add cup holders.. build them into the door

Your doors are quite a bit shorter than mine, but these cup holders are perfect. I'll try to get a better picture tomorrow lol



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I may do cup holders. I just hate to cut a hole in the diamond plate. It would take away the strength. If I do it will be out of PVC to help the temp of the beverage stay cooler.

Totally digging the look! Do you have any measurements of the rear door? The front are a little too low for me, but really like how the rear doors look.
Thanks!!!!!

Got them pretty much finished. few fine tweaks to make them open and close perfectly. Here are a few pics
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Looks sic bro, nice work!

Wow came out very well!!!

Thanks

Thanks. I still have another coat of clear to put on them and I am working on ideas for secondary latches.