New Used Half Doors for my 04 TJ Rubicon

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KDB9000

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I figured I would post my project/experience for half doors on my 2004 Jeep Wrangler Rubicon. I purchased my 04 Jeep TJ Rubicon in 2017 used from a Ford Dealership. The Jeep was original built and exported to Canada, so it has some things related to Canada laws (like daytime running lights) and had a KPH speedo (although when I got it the cluster had already been swapped out to MPH US based cluster by US Speedo, including the Mile conversion based on the Car Fax). It was built with the dual top (although it only had the hard top when I got it) and full doors only.

I plan on getting a soft top and have wanted to get half doors, but it isn't easy to find good condition half doors in the correct color and with the correct color inside panels. So I figured I would get some doors, clean them up, repaint them, replace any parts needed, and then I would have some new to me half doors. Since some people might be looking for half doors as well, I figured I would share my experience and the project in case some people we on the fence about it.

I will try and post as often as I can, but it is going to be a slow process as I get parts in and have the time to work on them. I will try and give an account for how much it cost and answer any questions that people might have. And with that, let the project begin.

The half doors I got came from eBay, white in color with gray interior. I was hoping to find some doors close to the color of my Jeep (Sienna Pearl Coat), but the only set of red doors I saw didn't have the key cylinder. I have found some online, but I have had a hard time finding the correct retaining clip for my Jeep year. I think it is possible to use one from another year, but I didn't want to chance it. The price difference wasn't too big between the doors. With shipping (which was free), the doors cost me about $600. I know that might sound expensive for used doors that are not in perfect condition, but that is about the price you will pay for used ones and in possibly worst condition.

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The seller did indicate a little dent just behind the exterior door handle, some scratches, some surface rust, and that one door had been repainted (not very good they noted). This was mainly on the Driver door, the passenger didn't seem to have anything wrong. When I got the doors, they looked just like the images so I was happy with that. I did a test fit of the passenger door to make sure everything was good. That is when I found the first issue not listed. The lower pin seemed to be bent a little so it wouldn't go into the hanger. The driver door also seems to have a dent in the top part of the door. The interior panels were alright, just need to be cleaned up. I plan to repaint them to the dark slate gray so it matches my current interior. The footman loop on one door wasn't attached, but was in the box. Looking closer, it looks like the bolts snapped off.

Currently I am stripping the door down of the parts so I can clean and start stripping the paint off to get it ready for repaint. I am debating if I am just going to use rattle can spray pant or spend some extra money on a spray system and do something similar to professional (which can be used later as I have plans to replace the front fenders, or fix). I did find a place to order the paint in my color for either way, so I have options available.
 
Having undertaken this project, I figure you already know this, but thought I'd mention it just in case...

Make sure to make all the adjustments to the door hinges to get the fit & latches working as expected prior to painting the doors...I speak from experience...:confused:
 
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glwood said:
Having undertaken this project, I figure you already know this, but thought I'd mention it just in case...

Make sure to make all the adjustments to the door hinges to get the fit & latches working as expected prior to painting the doors...I speak from experience...:confused:
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Thank you for the info. That was what I was planning as I have noticed that they have the hinges on when they painted (no paint under the hing). So once they are stripped I plan mount them on the door and get the hinges secured before primer and paint. It is nice to hear I am not the only one who has decided to take on a project like this.
 
KDB9000 said:
Thank you for the info. It is nice to hear I am not the only one who has decided to take on a project like this.
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No problem. I made the mistake of assuming all doors fit all TJs the same, and proceeded to have them painted as received. They were even doors I personally had on a previously owned TJ. I should have put the doors on first, made all the adjustments, then had them painted...
 
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glwood said:
No problem. I made the mistake of assuming all doors fit all TJs the same, and proceeded to have them painted as received. They were even doors I personally had on a previously owned TJ. I should have put the doors on first, made all the adjustments, then had them painted...
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Can you please explain a little more? From what I see in all half door postings, they say "will fit 1997 - 2006." What is the adjustment that is necessary? And is this adjustment necessary for all years, or some years? For example: 1997 - 2002 fit one way while 2003 - 2006 fit another. Thanks.
 
Flib said:
600 hundred bucks, I bought mine which were in really good shape for 100.View attachment 103513
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It’s a common price in the United States. In Nova Scotia, some parts must be cheaper. Its rare to find half doors in great condition(as yours look to be) for that cheap here in the United States. It happens, it’s just rare. Good find.

Would you flip them for $300? I’ll pay shipping. 😉
 
Fouledplugs said:
It’s a common price in the United States. In Nova Scotia, some parts must be cheaper. Its rare to find half doors in great condition(as yours look to be) for that cheap here in the United States. It happens, it’s just rare. Good find.

Would you flip them for $300? I’ll pay shipping. 😉
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lol, not a chance :)

I think the parts being cheaper here may have to do with rust, more rusted out Jeeps being taken off the road means more parts available or something, and just sometimes you find what you need that is not rusted to heck.
 
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KDB9000 said:
Thank you for the info. That was what I was planning as I have noticed that they have the hinges on when they painted (no paint under the hing). So once they are stripped I plan mount them on the door and get the hinges secured before primer and paint. It is nice to hear I am not the only one who has decided to take on a project like this.
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I'd prime and paint both where the hinges mount and the back side of the hinges themselves before putting them on. Just some Rustoleum or whatever would be better than two pieces of bare metal trying to keep each other from rusting. Then make any needed adjustments. Then get the doors painted.
 
Byhumba said:
Can you please explain a little more? From what I see in all half door postings, they say "will fit 1997 - 2006." What is the adjustment that is necessary? And is this adjustment necessary for all years, or some years? For example: 1997 - 2002 fit one way while 2003 - 2006 fit another. Thanks.
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Like I said, I assumed they would work fine, so I had them painted. Then when I went to install them, the driver side door latch did not line up with the striker on the jamb. So I had to loosen the door hinge bolts with the door on the TJ, lift the rear of the door until it was lined up, then tighten the bolts. It took a couple of tries to get it working right. Of course, loosening the bolts and adjusting the hinges on the door messed up the new paint on the hinge bolts, plus now an unpainted part of the door was showing, due to moving the hinge to adjust. That's why I recommend getting all the adjustments, which require loosening the hinge bolts, done prior to painting the half doors. You might get lucky, and not need any adjustments, but don't assume this, as I did. The doors will 'fit' all years of TJ, but that doesn't mean they won't need to be adjusted to close as they should. Make sense?
 
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X2 on what glwood said about getting fitup right before painting. Every Jeep can be different.

I recently bought a set of oem half doors for $100. They were in decent shape, horribly dirty, but the right color for me. The passenger one had a bent spot on the very rear top corner, I have straightened it out. The more I cleaned them, the better I liked them. Not going to repaint at this time.

Got new door handles from crown, and sourced an oem Jeep mirror from eBay. Painted the interior panels with Bulldog adhesion promoter, then massey red from TSC.

The paracord door handles are from georgiamountaincord on eBay. Excellent product, can order any color combo you want. I also have a set of door limiting straps coming from them as well.

So after purchasing missing parts, painting, and buying aftermarket soft skins/frames, and rekeying my lock barrels, I'm into my half doors for $530. Either way it adds up, but at least you know what you've got after refurbing a pair.

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glwood said:
Like I said, I assumed they would work fine, so I had them painted. Then when I went to install them, the driver side door latch did not line up with the striker on the jamb. So I had to loosen the door hinge bolts with the door on the TJ, lift the rear of the door until it was lined up, then tighten the bolts. It took a couple of tries to get it working right. Of course, loosening the bolts and adjusting the hinges on the door messed up the new paint on the hinge bolts, plus now an unpainted part of the door was showing, due to moving the hinge to adjust. That's why I recommend getting all the adjustments, which require loosening the hinge bolts, done prior to painting the half doors. You might get lucky, and not need any adjustments, but don't assume this, as I did. The doors will 'fit' all years of TJ, but that doesn't mean they won't need to be adjusted to close as they should. Make sense?
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Thanks for the reply. I bought some half doors. They are in decent shape, no rust and very minor dents. I want to paint them silver as they are currently dark blue. I was about to take them to a paint shop and your comment made me check the fitment. (Thanks).

I noticed that the upper pin (upper hinge) drops (sits) all the way in but the lower one stays up/out about 0.5in and the door doesn't close as the latch is misaligned. This happens on both doors. It made me think that I bought earlier (97 - 02) TJ doors and my Jeep is the later generation (03 - 06). I put them on CL for sale, but I may reconsider that and just adjust them. I may also just replace the hinges with stainless steel ones (still debating). Thx
 
Byhumba said:
Thanks for the reply. I bought some half doors. They are in decent shape, no rust and very minor dents. I want to paint them silver as they are currently dark blue. I was about to take them to a paint shop and your comment made me check the fitment. (Thanks).

I noticed that the upper pin (upper hinge) drops (sits) all the way in but the lower one stays up/out about 0.5in and the door doesn't close as the latch is misaligned. This happens on both doors. It made me think that I bought earlier (97 - 02) TJ doors and my Jeep is the later generation (03 - 06). I put them on CL for sale, but I may reconsider that and just adjust them. I may also just replace the hinges with stainless steel ones (still debating). Thx
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The fact that the hinge pins are in different depths shouldn't matter too much. I'd certainly try loosening the hinge bolts on the door and attempting to adjust the door to the striker. There really can be a lot of adjustment done. Get someone to help you hold it where it needs to stay while you tighten up the hinge bolts. Loosening the door hinge bolts might actually help solve the different pin depth issue also.

What's ironic is I also had dark blue doors I had painted silver...worth trying to adjust them first before selling them, if you really want half doors. I can link my thread about my door project if you're interested.
 
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glwood said:
The fact that the hinge pins are in different depths shouldn't matter too much. I'd certainly try loosening the hinge bolts on the door and attempting to adjust the door to the striker. There really can be a lot of adjustment done. Get someone to help you hold it where it needs to stay while you tighten up the hinge bolts. What's ironic is I also had dark blue doors I had painted silver...worth trying to adjust them first before selling them, if you really want half doors. I can link my thread about my door project if you're interested.
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Please do. It will help me, and others I'm sure.
 
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