so i decided to do something a little different than your normal tube doors.

i chose to make lightweight sheet metal door that i could bedline to match the jeep and weld in some storage boxes and even weld a cup holder to it. and maybe an armrest

the object is to mimick the wrangler soft doors, but with sheet metal


so i picked up some 3/16" round stock and some 1/8" sheet metal and got to work.


first i cut out a template of the shape i wanted out of cardboard (not pictured) then bent out some pieces to match and welded them up.



so far it opens and closes smoothly without any up and down play


that is as far i got today, tomorrow i may be able to cut out the shape i want from the sheet metal and weld it to the frame i built.

 

Very cool. I just might have to do that to all four doors. I wish i had good photoshop skills so I could convince my wife to let me do it.

 

great idea and looks good so far. continue to post pics because i really want to see how these turn out. (i might even copy you a bit)

 

Well, I have good Photoshop skills, lol. Maybe you could send me some pics, and I could build the convincing picture you're needing to convince your wife. Just a fellow forum friend trying to lend a hand to an enthusiast with an idea, and an unconvinced significant other. Believe me, I fight those battles all the time, hahaha.

 

Lol thanks man. Only problem is we are in the final stages of purchasing a home so I doubt ill get to do this any time soon.

 

well, if it helps...ive only got $30 into this project so far for materials

 

That always helps. The problem is moving everything we own, painting, putting up a fence( only half acre but still) and getting settled in. My wife and I also want to build a deck out to the pool and a playhouse for the kids so I'm sure I'll be tied up for a long while.

 

Hello,

Very cool so far.
Nice easy low cost solution, looking forward to seeing the final.
You will find as you experiment you come up with all kinds of ideas and add on's the right one will be much better.
I always start on the right side and end on the driver side.

Nitro

 

Have you thought about covering on a black vynil and put snaps on it. Wrap the edges in snaps, roll the material over the edges and snap to the other side?

 

haha, yea....only reason i started on the driver side is i just backed my jeep up to the bay door and the driver side was closest


the thought has crossed my mind, in fact i even mocked up an old soft top we had in the shop to get an idea of how it would look. but, for this project i think ill hold off. the cost for the vynil and snaps are more than i wanted to throw at these doors. and i "think" the bedlined sheet metal will blend well enough and look decent...but we will see

but, i could always add them to the finished doors, or even build another frame easy enough and use it on a second set of doors.

 

so i started drawing up the latch system, cup holder, and storage pocket. and im pretty happy with out it should all look and work.

so hopefully monday i will be able to jump back on this and finish at least one door.

 

so i made some progress today, but managed to run out of welding gas before finishing completely.

the latch system is done and works great. and i started welding the sheet metal to the frame, but only was able to finish the top row. i still need to finish welding it all around and add a sheet metal patch to the end, which i only have to do because the sheets i have werent long enough. so ill weld that up and smooth it all down to look like 1 piece.

also, i still need to fab up my cup holder, storage net box, and inside door handle...oh and bedline it to match the jeep


the latch works by just pushing down on the handle

 

Looks like they should turn out pretty good. I keep thinking of doing tube door just so it would be easier to see the front wheels coming up on rocks but this maybe the way to go.

 

Nice. I've been trying to come up with a half door idea forever. Very difficult when you have no tools or supplies.

 

yea, im still undecided on them. i like tube doors and i still may build a set for this jeep. but, i just wanted to try something i havnt really seen yet.

the visibility is pretty good with them, i can see my tire pretty easy.

make friends with people who have the tools.