Full door disassembly and restoration

[TJRD4]

Looking to see if anyone has any experience with restoring a set of full doors. Picked up a used pair; overall good shape, one has a little rust on the bottom seam.

I see summit sells replacement doors skins now so maybe one less thing to

I’d like to disassemble the handle/lock/window etc and strip it down for painting. Figured I’d ask if there’s a good how to before I start removing bolts!

Appreciate the help!

 

[GATORB8]

Looking to see if anyone has any experience with restoring a set of full doors. Picked up a used pair; overall good shape, one has a little rust on the bottom seam.

I see summit sells replacement doors skins now so maybe one less thing to

I’d like to disassemble the handle/lock/window etc and strip it down for painting. Figured I’d ask if there’s a good how to before I start removing bolts!

Appreciate the help!

Too bad your Jeep isn't black, my full take offs are in really good shape.

I just did the halves, only real difference I'd expect would be the window regulator.

I replaced the outer and inner handles, you may want to do the same, the little plastic retainers can break when you take it apart.

The OEM hinges are painted on the door, IF you remove them be careful because the paint+age makes the torx prone to strip (I've done it on two generations of wranglers at this point).

Pull the panel before messing with locking/latching/handles, the door cards are cut out around them unlike some later models.

I used rockauto for weatherstrip, QT for handles, new philips: https://www.amazon.com/dp/B0C3RPCMCM?tag=wranglerorg-20 , new christmas trees: https://www.amazon.com/dp/B0B1LN2SL4?tag=wranglerorg-20

 

[lBasket]

Find a way to reinforce where they crack

 

[TJRD4]

Too bad your Jeep isn't black, my full take offs are in really good shape.

I just did the halves, only real difference I'd expect would be the window regulator.

I replaced the outer and inner handles, you may want to do the same, the little plastic retainers can break when you take it apart.

The OEM hinges are painted on the door, IF you remove them be careful because the paint+age makes the torx prone to strip (I've done it on two generations of wranglers at this point).

Pull the panel before messing with locking/latching/handles, the door cards are cut out around them unlike some later models.

I used rockauto for weatherstrip, QT for handles, new philips: https://www.amazon.com/dp/B0C3RPCMCM?tag=wranglerorg-20 , new christmas trees: https://www.amazon.com/dp/B0B1LN2SL4?tag=wranglerorg-20

Thats great info on the screws; i spent a good amount of time trying to find them for the dash speaker enclosures and the cheapest i could find was QT at $3.49 per and I wasn't about to spend that.

The FSM has some information on disassembly so i guess ill start with that.

 

[TJRD4]

Find a way to reinforce where they crack
View attachment 649618

I read that the YJ doors had cracking issues didnt know it was the TJs too... ill have to take a closer look at mine now... ugh

 

[lBasket]

I read that the YJ doors had cracking issues didnt know it was the TJs too... ill have to take a closer look at mine now... ugh

Both of mine are split right there. I need to pull them apart and weld something in there, but, lazy

 

[Rickyd]

Both of mine are split right there. I need to pull them apart and weld something in there, but, lazy

Good reason to close them gently. They aren't as robust as most vehicles

 

[GATORB8]

Thats great info on the screws; i spent a good amount of time trying to find them for the dash speaker enclosures and the cheapest i could find was QT at $3.49 per and I wasn't about to spend that.

The FSM has some information on disassembly so i guess ill start with that.

Yeah, I was looking at some old threads and someone mentioned the thread pitch and the captive washer, and it popped right up on amazon.

You don't really need the long ones, but there's so many it didn't really matter.

Grab a crank remover if you don't have one. Everything on halves was Torx or basic Philips.

 

[lBasket]

Good reason to close them gently. They aren't as robust as most vehicles

Or to leave them in garage

 

[MikekiM]

I did an extensive restoration on half doors.
I have a long thread here.
If you think there would be anything of value... I will dig up a link.

 

[chili_pepper]

Find a way to reinforce where they crack

I was under the impression this was a result of running top off with full doors, without the plastic surrounds in place.

 

[lBasket]

I was under the impression this was a result of running top off with full doors, without the plastic surrounds in place.

I've never taken my hard top off and not gone to half doors, I had them before a soft top. But who knows about the PO I guess

 

[chili_pepper]

I've never taken my hard top off and not gone to half doors, I had them before a soft top. But who knows about the PO I guess

Feel like I read or heard it somewhere, could be complete BS. Same as you, no idea about the PO, but mine came pre-cracked.

 

[Imagineer]

I was under the impression this was a result of running top off with full doors, without the plastic surrounds in place.

I just had to weld up both of the POS full doors in that same spot. One of the doors also cracked at about the middle of the inside window opening. The metal is really thin there.

 

[SSTJ]

How is this coming along? I’m actually in the middle of this myself right now. Just painted the interior panels and replaced the interior handles. Adjusting the hinges has been a bit of a nightmare but I think the doors will finally shut correctly.

I was just signing on to look for recommendations of new exterior handles.

 

[FarFire70]

Both of mine are split right there. I need to pull them apart and weld something in there, but, lazy

Good reason to close them gently. They aren't as robust as most vehicles

Mine both have cracks at the window loop. I think it's an artifact of using the loop to carry the doors.

I try to do that less but it's so convenient to use when moving them around...

 

[lBasket]

Mine both have cracks at the window loop. I think it's an artifact of using the loop to carry the doors.

I try to do that less but it's so convenient to use when moving them around...

I like to roll the window down and put the top of the door over my shoulder

 

[FarFire70]

I like to roll the window down and put the top of the door over my shoulder

Same - but I think that's a major cause of the cracks. Puts all the heavy with of the door on those joints...

Mine are just minor cracks but show rust within - so likely worse than the surface shows.

I just picked up used OEM doors that don't have any cracks and I think my new approach will be to keep the windows rolled up when removing them to avoid causing it exactly this stress on the doors.

Way more of a pain to lug them around, but avoids stress, cracks and future body work...

 

[lBasket]

Same - but I think that's a major cause of the cracks. Puts all the heavy with of the door on those joints...

Mine are just minor cracks but show rust within - so likely worse than the surface shows.

I just picked up used OEM doors that don't have any cracks and I think my new approach will be to keep the windows rolled up when removing them to avoid causing it exactly this stress on the doors.

Way more of a pain to lug them around, but avoids stress, cracks and future body work...

I think its from slamming them, personally. I definitely like to give my doors a good hearty shut

 

[FarFire70]

I think its from slamming them, personally. I definitely like to give my doors a good hearty shut

I think that can't help but I'm still in the camp it's about carrying them by the hoop.

Think about how heavy door is, and you're tossing that weight around by the loop when you toss it over your shoulder (like I do). That's a lever moment on the the loop joins the door.