Trail Doors!

[RFR2212]

Well this is for my '73 Bronco, but the same principles apply to explorer doors for the most part.
Here's the full door:

Here's the partially filled door:

It's quite simple. Get large sawzall blades and cut whatever you want removed. I started with a sawzall and the door became so flimsy, that it shook violently with the saw. I then used a cut off wheel. Presto! I then used a portion of the door sheet metal for the bottom plate and have other sheet metal for the other portions of the door. I simply shape them in a vice with a mallot and then drill 9/64 holes for my 1/8in rivets. Works very well. Place a rivet every 1 to 1.5in and you're set. File any edges with a file so you dont catch your arm and cut yourself. Yes, you could weld the sheet metal in and then fiberglass over it and smooth it out to make it purdy, but that is not necessary for the truck.

With the bronco setup, the outside door handle will still work, which was important. You may also ask, why not build tube doors? Well the reason is, I've already got the doors and sheet metal, so it's an easy project.I also didn't want to install the full doors because I have no permanant roof. So they then become kinda clumsy. Bugs were eating me, so I did not finish the pass. door tonight. Tomorrow, I will finish it, and hopefully cut down the drivers door. A brief writeup but there isn't much too it. I will follow it up with more photos as I progress.

 

[Desert Rat]

Thats a cool idea, but how strong is the door after all that cutting?.....

 

[RFR2212]

It's very weak initally, but each new piece of sheet metal makes it stronger. I will let you know once I get the last piece in. I'll check how much it flexes and twists.

 

[Burns]

nice idea i have seen it before and i have thought about it one the X but i need a way to make cover with a window in it

 

[younggun]

here are some doors off of a buddies 79 f150.

 

[RFR2212]

Here are the last pics I took last week when i was working. Been too busy since then to work on the drivers door. However, I've changed the drivers side a bit. I am building the sides first, and will then cover the bottom last.
Pass side done

drivers side

I think these should turn out pretty well...

 

[badmonkey]

Very cool

 

[410Fortune]

just weld them to the bronco tub!

oops....I bet you cant guess what the BII's gonna get

 

[Desert Rat]

Nice work........Ive been thinking about trail doors myself instead of tube ones.

 

[RFR2212]

See, now if I wanted to do that, I'd have cut them ALOT more. Never thought of the idea, but I suppose if I do make the truck streetable, I'd like to yank the doors off...

just weld them to the bronco tub!

oops....I bet you cant guess what the BII's gonna get

 

[RFR2212]

Here's the drivers door finished. Both good and bad came out of this door. I put the bottom piece on last, so I think it looks cleaner, but I didn't leave myself enough metal for the inside of the door on the one end, so I torched it alot and kinda mashed it around. It'll work. Next week I should have installed pictures.