Another Half Door Option

[JMT]

Did you just buy your own sheet of aluminum and make your own armor so the cutout matches the handle?

Yes, I just bought a sheet of Aluminum that I could cut two door skins out of. Cut the holes for the door latches. Works.

I also welded an arm rest out of square tube to the inner door frame. I'll post a pic in a sec. I'd tell you the rest of my plan, but then I'd have to kill you.

 

[kmas0n]

Your project looks great BTW, I am following. I was interested in the Aluminum rods and brazing you did. Looked into that and may do some. I hope your brackets for the aluminum radiator holds up. Super cool build.

Thanks. so far so good!

 

[kmas0n]

Yes, I just bought a sheet of Aluminum that I could cut two door skins out of. Cut the holes for the door latches. Works.

I also welded an arm rest out of square tube to the inner door frame. I'll post a pic in a sec. I'd tell you the rest of my plan, but then I'd have to kill you.

View attachment 690292

Did you paint the steel frame and sheet to look aluminum?

 

[3jeepfan]

One could weld several tabs to the steel door frame. Then bolt the aluminum skin on. Just skip the sheet of steel. Maybe use a heavier aluminum to gain strength

 

[JMT]

Did you paint the steel frame and sheet to look aluminum?

Yes, I used a spray can Blaine mentioned that looks very close to aluminum. I can get the name if someone is interested.

For the interior I have planned a super thin inner aluminum skin and that's where I'm going to put all my stickers from companies. Just a fun thing. Nothing substantive there.

 

[3jeepfan]

Do your doors rattle? I have the soft half doors, & the latches rattle on the latch pins. And the doors fit tight because of door seals. drives me crazy sometimes!

 

[JMT]

Do your doors rattle? I have the soft half doors, & the latches rattle on the latch pins. And the doors fit tight because of door seals. drives me crazy sometimes!

I have experienced that when I had these doors on a TJ. I had some XJ weather stripping that fit perfectly on the steel rod frame of the doorand it stopped all that.

Moved on to this LJ and never had an issue.

 

[3jeepfan]

My half doors fit tight enough that my wife has trouble opening them from the inside. But the damn latches still start rattling after a while! I've tried a piece of gorilla tape around the post, which was a temporary fix.

 

[JMT]

My half doors fit tight enough that my wife has trouble opening them from the inside. But the damn latches still start rattling after a while! I've tried a piece of gorilla tape around the post, which was a temporary fix.

There's a fix where you take some 3/8" plastic tubing and put it on the U latch (tub side). I'd have to look it up to be 100% on the size, but it's on here somewhere.

 

[3jeepfan]

Thanks, it's worth a try. Almost half door season!

 

[MikeE024]

There's a fix where you take some 3/8" plastic tubing and put it on the U latch (tub side). I'd have to look it up to be 100% on the size, but it's on here somewhere.

Thanks, it's worth a try. Almost half door season!

3/8" nylon airline works great with the Savvy half doors. Blaine has been telling us to do this for many years.

 

[Apparition]

3/8" nylon airline works great with the Savvy half doors. Blaine has been telling us to do this for many years.

The newer Savvy latches also minimize any rattle.

 

[MikeE024]

The newer Savvy latches also minimize any rattle.

View attachment 691049

That's interesting. Do you still use some airline or is it not necessary?

 

[Apparition]

That's interesting. Do you still use some airline or is it not necessary?

No, not any more. The rubber in the latch seems to work.