My latest item for this build is a set of half doors. My "full" doors are super straight and I am always worried about ruining them...so usually they come off in the summer for EVERY wheeling trip (which gets tedious.) I wanted something that will keep things like water bottles, cell phones, etc inside the truck in off camber situations as well as something that I won't have to worry about damaging too much.
I picked up a set of doors from a Bronco II off craigslist for $25. I immediately started stripping everything off of them, leaving only the door latch assembly. Window tracks, lock, etc are all gone. The inside handle is gone too. I don't mind reaching out to open the door, so after gutting them, I cut the window frame off and notched the door so I ended up with this:
After that, I put them away for a couple weeks while I gathered materials, which consisted of some 1.25" angle from a bed frame and some sheet steel from a Lincoln hood that I repurposed. Next, cut angle, weld in as a frame around the notch...
This makes the door really stiff. It was really floppy after cutting the window frame away. Next, fill in the lock cylinder hole...
Then cut a piece of the Lincoln hood, measure, and bend so that it fits in the notch.
I used two pieces for this. I could have used one but my hood section wasn't long enough. I welded all the way around and used a ball peen hammer to form the sheet steel to the notch. After that it was just a matter of cleaning up the welds and grinding them smooth.
I am half done with one door right now. I will be welding a large section of steel on the inside to cover up all the holes. Then going through with body filler for the low spots and lock cylinder hole before I sand and paint. More to come as time allows!
