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

Old 07-15-2014, 11:58 PM
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Default 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
Half Doors Build (Really 1/3rd) no welding-1.jpg

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
Half Doors Build (Really 1/3rd) no welding-2.jpg

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.
Half Doors Build (Really 1/3rd) no welding-5.jpg

Here is a shot while i was still working on getting the cut right.
Half Doors Build (Really 1/3rd) no welding-7.jpg

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.
Half Doors Build (Really 1/3rd) no welding-8.jpg
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Old 07-16-2014, 12:10 AM
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Pic of the rear door inner brace

Half Doors Build (Really 1/3rd) no welding-9.jpg

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.
Half Doors Build (Really 1/3rd) no welding-11.jpg
Half Doors Build (Really 1/3rd) no welding-12.jpg
Half Doors Build (Really 1/3rd) no welding-14.jpg

Here is where it got pretty clean. I figured I could easily use the door panels for looks and use the storage space.
Half Doors Build (Really 1/3rd) no welding-17.jpg
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Old 07-16-2014, 12:17 AM
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Those are sweet. I love the diamond plating
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Old 07-16-2014, 12:18 AM
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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.
Half Doors Build (Really 1/3rd) no welding-22.jpg

Half Doors Build (Really 1/3rd) no welding-21.jpg

Half Doors Build (Really 1/3rd) no welding-23.jpg

Half Doors Build (Really 1/3rd) no welding-24.jpg

Half Doors Build (Really 1/3rd) no welding-19.jpg
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Old 07-16-2014, 12:24 AM
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Originally Posted by Themrjsmitty View Post
Those are sweet. I love the diamond plating
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.
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Old 07-16-2014, 04:17 AM
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Perfect time to add cup holders.. build them into the door
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Old 07-16-2014, 04:22 AM
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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



Half Doors Build (Really 1/3rd) no welding-forumrunner_20140716_022155.png
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Old 07-16-2014, 08:18 AM
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Originally Posted by torque062 View Post
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
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.
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Old 07-16-2014, 09:55 AM
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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!!!!!
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Old 07-16-2014, 08:07 PM
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Got them pretty much finished. few fine tweaks to make them open and close perfectly. Here are a few pics
Half Doors Build (Really 1/3rd) no welding-32.jpg

Half Doors Build (Really 1/3rd) no welding-33.jpg

Half Doors Build (Really 1/3rd) no welding-34.jpg

Half Doors Build (Really 1/3rd) no welding-36.jpg

Half Doors Build (Really 1/3rd) no welding-37.jpg
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Old 07-16-2014, 08:30 PM
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Half Doors Build (Really 1/3rd) no welding-35.jpg

Half Doors Build (Really 1/3rd) no welding-20140716_162750.jpg

Half Doors Build (Really 1/3rd) no welding-37.jpg
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Old 07-16-2014, 09:27 PM
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Looks sic bro, nice work!
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Old 07-17-2014, 04:58 PM
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Wow came out very well!!!
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Old 07-17-2014, 05:10 PM
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Originally Posted by Gary Briggs View Post
Looks sic bro, nice work!
Thanks
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Old 07-17-2014, 05:11 PM
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Originally Posted by stitch702 View Post
Wow came out very well!!!
Thanks. I still have another coat of clear to put on them and I am working on ideas for secondary latches.
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