[Jeonlyep]

Here's how I did mine....

1. Start the cut at the back of the door, 2 inches in, even with where the factory door folds in to the window. leave the window track in place.

Photo 1

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Cut following a straight line down from the factory fold. It ended 2.5 inches in (photo 2) , and 9.25 inches (photo 3) up from the top fold on the door bottom. (photos misleading due to angle of door in relation to the camera)

Photo 2

Photo 3

2. Cut the front on a line that parallels the front of the door edge 4 inches in. (photo 4) To a point 4.5 inches up from the top fold on the door bottom

Photo 4

3. Cut a line that parallel the top fold on the bottom of the door at the 4.5 inches, back 16.5 inches from the front of the door.

4. Cut a line that parallel the top fold on the bottom of the door at 9.25 inches 17 inches in from the back of the door.

5. That should give you 6.5 inches for the angle where the door handle will go. (photo 5)

Photo 5

6. Cut (6x8.5) and folded (to 4x6.5) a piece of 16 gauge steel, and welded it into place for the angle. (photo 6, 7)

Photo 6

Photo 7

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7. Cut (6x15) and folded (to 4x15) a piece of 20 gauge steel, and welded it into place for the arm rest. (photo 8, 9)

Photo 8

Photo 9

8. Cut (6x12.5) and fold (to 4x12.5) a piece of 20 gauge steel, and weld it into place below the door handle angle. (photo 10)

Photo 10

9. clamp a piece of steel to the front of the door. Mark for where to bend and or cut. (photo 11)

Photo 11

 

[Jeonlyep]

10. Cut a piece of .75 tubing to fit the window tracks. Bow the tubing to follow the bend in the window tracks for the front and rear. Weld the tubing into place. (photo 12), (I used a big rubber hammer)

Photo 12

11. Bend .5 inch lip on some 20 gage steel and fit to the gaps on the sides of the tubing. (I clamped the .5 lip to the tubing then marked the steel. Cut it then welded it into place.)

12. Cut a hole for the door handle. Use a 3/4x1/8x6 inch piece of steel bending it 1 inch from each end. (I threaded 2 long bolts into the door handle, and cut off the heads to use as guides to hold the handle in place, and drilled a new hole for a .25 bolt to pinch the handle onto the door. (photo 13, 14) The handles I used were from a Gremlin, but AMC used these a lot and Jeep used them on some TJ's and YJ's tail gates and some factory steel doors.

Photo 13

Photo 14

13. Reuse one of the latch rods, bend it to fit the door handle.

14. You can make a cup holder using a 3 inch PVC pipe cap and a 3x2.5 PVC pipe bushing. Cut a hole to let the bushing fit through the door and glue the cap on from inside the door. (photo 15)

Photo 15

Photo 16

15. Bondo and paint. (photo 17, 18)

Photo 17

Photo 18

Other photos

 

[Jeonlyep]

Total door options

 

[Kyle]

Moved to the correct section, thanks for the writeup:cheers:

 

[Jeonlyep]

Opps, my bad....

 

[mudbath81]

awesome write up. ive been looking everywhere for this!

 

[Belto]

nice write up, ive seen it before, your pretty popular bc of it.. LOL

 

[Jeonlyep]

620 Fab will build em for ya, if you don't want / can't build em yourself....

PM for contact info......

 

[dbperformance96]

Those turned out awesome. This is on my list of things to do. Thanks for the pics.

 

[jakeWI]

awesome write up

 

[johnnyrossman]

Awesome!!! Better than $400 mail order

 

[1488pride]

awesome write up. they look good these are on my to do list.:rock:

 

[PolarXJ]

Nice write up, I think I have to go this route and opposed to the completely doorless mod. It doesn't sit well with the mrs. to not have the door in.

 

[boneheadzz]

Love the low buck cup holders! Slick...

 

[jfxj67]

NICE!!! :thumbsup::thumbsup:

 

[jramey]

Very nice, maybe one day ill do this