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Has anyone attempted to make their own hard doors?

McSpeed

McSpeed

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Palmer, AK
So...we had a historic snow storm this week - feet of snow around my house - hours and hours in the driveway just getting it cleared last night. I'm wondering if this will delay the receipt of the hard doors....should be here tomorrow. The hardest part will be likely the door striker install. I still have to decide on paint or no paint...etc. The truck is faded so if I paint fresh the doors in the woodland camo - it won't match the rest. If I go black or just green - that might be okay. Clear coat on the aluminum might be sweet too. Just totally undecided. My local 4x4 crew is going on a very difficult off-road trail this weekend. Not sure if it will be ready for that or not - The door comes with adhesive weathestrips that are one time use - so if I am to use them and paint - I should only install them AFTER I paint...Anyway.....
 
thoner7

thoner7

Active member
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Location
NE TN
McSpeed said:
Just an update on this thought process. We have an RV manufacture plant near us and I visited them yesterday afternoon. They sell raw materials to the public including the various gauge of aluminum and fiberglass that they skin RVS and windows. I can get a sheet of 8' by 8' Fiberglass skin for about $330. That would be enough to skin four doors. It can be painted, glued, screwed, riveted, and modified and or repaired with standard fiberglass technique.

They also have RV slider windows. Looks like a 15x30 is the most common in-stock horizontal slider. However, actual size it about 31x16 outer lip to outer lip and while it would be wonderful to have such a large window - that won't fit...or not at least as I can currently tell.

They also have door handles of various types - I need to go to a flush mount to keep from snagging and breaking one off when I'm off road.

I also called the local metal supply - They have all sorts of sheet aluminum. I can to a 1/4" or 3/16" for about $350 per 4x8 sheet - would need two sheets. This would require costly metal cutting blades but would not require the use of the existing soft door frame. the 3/16" would weigh around 25 lbs per door before any hardware. This could be made to fit more flush - put a bend at the belt molding area to make it fit the cab, but you are back to the same window issue.

More research and thinking to do....
Click to expand...
What RV manufacturer are you near? I have an m1165 coming soon(!!!) and I want to get a window made for the rear wall.
 
thoner7

thoner7

Active member
313
196
43
Location
NE TN
I’m not in Alaska, so I’ll try to find someone near me. Just wondered if anyone made a window
 
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