Things You'll Need:
- 3/4" Steel tubing
- Diamond plate
- Jig Saw or Plasma Cutter
- Welder (Preferred)
- Scrap Stock doors
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Step 1
The first thing you're going to need is frame. Start by creating a template for the door opening. The easiest is to have your junk yard doors on hand. Take your steel tubing and bend it to shape to create the outer frame of the door. Slow and steady with the pipe bender, constantly check your work against the junk yard door and the Jeep's door cavity.
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Step 2
Start at the top front side where the hinges are and then shape the bottom and rear side. Finish the top and join the two ends together. I suggest you weld them. You should be able to do it all with one 8' section of 3/4 inch of pipe. Use your first frame as template for your second.
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Step 3
Next choose what type of design you would like to cut in the diamond plate. If your a beginner I wouldn't get too crazy. Jig saws do the trick, but a plasma cutter makes quick work of the diamond plate. mmmmm,mmmmm, ..like a hot knife through butter.
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Step 4
Create a template for your design and cut out your shape. Remember, you need a place for the door handle. The door handle and hinges need to line up exactly. Check and double check your work. Use your scrap door to help line it up exactly.
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Step 5
Also, how are you going to attach the diamond plate to the door frame? If you are going to bolt or rivet it to the frame you must leave enough material do so. I wouldn't suggest it however. (Might as well just pitch the diamond plate and use plywood.) I suggest welding it together. It will give it the rigidity it needs as well as add that professional look.
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Step 6
Repeat for the other side. Keep in mind which side you are working on. No point to cut letters into the diamond plate if only the passengers inside the Jeep can read them.
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Step 7
Next install the door hinges. Regular stock Jeep door hinges will work just fine. Just bolt or weld them into place, starting with the top and then the bottom. Make sure the rear of the door is close enough for the door latch to reach.
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Step 8
Finally install the door handles and latch. Based of the measurements from the scrap door, the stock door handles should fit right in. Make sure the latches line up. Use you Scrap door as a model.
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Step 9
That's it! Go hit the streets and be the envy of your block. Whether you're going to tare up the trails or cruise to the corner to pick up some milk, you'll be doing it in style. Feel free to check out the links below for more information on Jeep doors and accessories.
