so luckily i have a replacement door, because the LAST bolt to take my door off wont budge for anything.. i'm going to have to cut right through the door and get to the back of the thread to cut that off too...

i pb'd everything.. blowtorch, wont budge.. i hate torx bolts they strip very easily.

anybody else have this prob?

 

I haven't tried to remove my doors, but I know what you mean when it comes to hating torx bolts. I stripped the ones holding my bumper on.

 

i cheat. i cut the hinge off the uniboady in a v so i can realign the cuts up easy later. when i have the door off i cut the bottom of the door side hinge so doors are removible from now on. the reweld the unibody side hinge on and your good to go.

i do this now because it is ten time easier than taking out the torx bolts.

 

And what weld it back on???

 

kinda of onfusing i know. instead of messing with the bolds i cut the part that is welded to the unibody off to get the door off. then weld the tab back on. sounds complecated but its really not. and 90% of them nee re welded anyway

 

cut the pin in the middle and hammer it out, u dont have to take the torx screw out at all,

 

yeah.. i was just going by the write up in the xj write up section in the tech section.

i guess i can just cut the top pin in the middle but doesnt the bottom pin have to be full length

also i gotta find a nice wire connector to make quick discos for the wires.

 

just use the disconnects that are already on the doors, ive been using mine for over a year now, can have the doors off or back on, in less than five mins

 

I had the same problem. I can tell you yanking the door off instead of dealing with the torx just creates bigger problems, like pulling the hinge outta the unibody

 

The only disconnects that are there are under the door panel, so i'd have to take the panels off and back on every time

And yeah i've got each door down to the last torx bolt but their both the same rusty bolt on the bottom of each side..

My new idea: go right through the hole in the door where the stock speaker is to the back of the torx bolt thread, with a "capped" nut, and wrench it outwards from the inside

 

Ok, solved some probs and created others lol, finally got the door off with and angle grinder, a sawzall, and some creativity.

Also, the factory disconnects behind the kick panel work fine (just need to cut the rubber filling in the hole through the body.

But i could not get my door back on. I tried nuts an bolts in place of the factory hinge pins.. Does NOT work out. Back at it tmrw. Any tips?