DIY doors

[Countryboy3220]

Since the mesh “doors” are kind of a pain I decided to make my own doors. I started with a cut out of cardboard and then traced it on to a sheet of 1/2” plywood. Then welded a frame out of 1/2” square tubing and flat stock. The hardest part was getting the correct arch on the flat stock (would have been easier with a bender. Then cut out 16 gauge steel for the skin of the doors. And welded 3/4” flat stock on top to cover the top rail of the doors. Bought hinges and latches I found on other threads, ordered off amazon. It was a little bit of fabrication but I’m only in about 300 dollars right now, still need paint but that will be in the spring. They aren’t perfect but they are perfect for around our farm. If you have the tools definitely worthwhile.

 

[Compshooter]

They'll keep the mud out! Nice!

 

[Campyman]

They look really good. A lot like the on the rox high end doors but 1/3 the price

 

[Lilsandyrox]

Great job!

 

[tuskermedic25]

They look great, there is a material called starboard, it's a waterproof thick plastic they use for boat construction and ad-ons. If I were handier with a saw, I would not only do a half door but full door. It's basically plastic plywood, and looks like high end fiberglass. They make doors, cabinets, tables on boats with this stuff, they call it plastic lumber, comes in many colors.

 

[Countryboy3220]

That would be awesome and then just use plexiglass for windows. I might have to look into that, if they had different colors.

 

[tuskermedic25]

That would be awesome and then just use plexiglass for windows. I might have to look into that, if they had different colors.

So the namebrand is starboard, but its also called kingboard, plastiboard, etc ect. Its not cheap, but its a better price than some of these aftermarket inflated prices. Your imagination is the limit with this stuff, center consoles, glove box, speaker boxes, doors.

 

[RoxorYooper]

They look really good. A lot like the on the rox high end doors but 1/3 the price

Some of the vendors prices are a bit ridiculous. I understand they do have a lot of overhead but at the beginning of the Roxor’s release I feel some vendors where taking advantage of people’s ignorance. I was quoted in July $1,200 for an Auburn limited slip differential when I replied I’d rather just buy the one I saw on their website for $340 they quickly changed the price to $400 (but their kit includes a ring gear spacer and crush sleeve eliminator) and said their price was based off the gear vendor supplier pricing and they were going to correct it by dealing with Auburn themselves. Seems like they would of known better with that much of a discrepancy.

 

[Jeepish]

You

Since the mesh “doors” are kind of a pain I decided to make my own doors. I started with a cut out of cardboard and then traced it on to a sheet of 1/2” plywood. Then welded a frame out of 1/2” square tubing and flat stock. The hardest part was getting the correct arch on the flat stock (would have been easier with a bender. Then cut out 16 gauge steel for the skin of the doors. And welded 3/4” flat stock on top to cover the top rail of the doors. Bought hinges and latches I found on other threads, ordered off amazon. It was a little bit of fabrication but I’m only in about 300 dollars right now, still need paint but that will be in the spring. They aren’t perfect but they are perfect for around our farm. If you have the tools definitely worthwhile.View attachment 2665View attachment 2666View attachment 2667View attachment 2668your doors are exceptional sir. Where did you source the latches?

 

[Jeepish]

They look great, there is a material called starboard, it's a waterproof thick plastic they use for boat construction and ad-ons. If I were handier with a saw, I would not only do a half door but full door. It's basically plastic plywood, and looks like high end fiberglass. They make doors, cabinets, tables on boats with this stuff, they call it plastic lumber, comes in many colors.

View attachment 2672

I was thinking of using a product I am familiar with called Phenolic. Used in a lot of architectural applications. It is primarily made of resin and holds up well to the elements.

 

[tuskermedic25]

looks legit, waterproof. They use it for bathroom doors and wall partitions, so they can hose them down.

 

[Jeepish]

Since the mesh “doors” are kind of a pain I decided to make my own doors. I started with a cut out of cardboard and then traced it on to a sheet of 1/2” plywood. Then welded a frame out of 1/2” square tubing and flat stock. The hardest part was getting the correct arch on the flat stock (would have been easier with a bender. Then cut out 16 gauge steel for the skin of the doors. And welded 3/4” flat stock on top to cover the top rail of the doors. Bought hinges and latches I found on other threads, ordered off amazon. It was a little bit of fabrication but I’m only in about 300 dollars right now, still need paint but that will be in the spring. They aren’t perfect but they are perfect for around our farm. If you have the tools definitely worthwhile.View attachment 2665View attachment 2666View attachment 2667View attachment 2668

Exceptional work. Where’d you get the latches?

 

[Peder53]

They look great, as far as hinges go, do the bolt holes on the Roxor match a CJ5 or 7 door hinge?

 

[Jeepish]

They look great, as far as hinges go, do the bolt holes on the Roxor match a CJ5 or 7 door hinge?

Looks like you’d have to get 2 sets of CJ bottom hinges per door. I have had trouble finding the part for the body and the part for the door as a set. Also, they are expensive. I have a possible alternative though: the hood hinges apear to be the same hole spacing. You can buy a set of CJ hood hinges with all the hardware on Amazon for $35. Not sure if the bolts that come with them are the same size and thread as the body holes though.

 

[Countryboy3220]

I found the hinges and latches on amazon, it was almost $140 for everything . I used to sets of the hinges but needed to open the holes a little bit for the holes to match the roxor. It requires different bolts that are metric. I’ll put up some pictures of the hardware I used.

 

[P Bleskey]

Since the mesh “doors” are kind of a pain I decided to make my own doors. I started with a cut out of cardboard and then traced it on to a sheet of 1/2” plywood. Then welded a frame out of 1/2” square tubing and flat stock. The hardest part was getting the correct arch on the flat stock (would have been easier with a bender. Then cut out 16 gauge steel for the skin of the doors. And welded 3/4” flat stock on top to cover the top rail of the doors. Bought hinges and latches I found on other threads, ordered off amazon. It was a little bit of fabrication but I’m only in about 300 dollars right now, still need paint but that will be in the spring. They aren’t perfect but they are perfect for around our farm. If you have the tools definitely worthwhile.View attachment 2665View attachment 2666View attachment 2667View attachment 2668

Been getting the components together to do a door build myself. Tell me, where did you get your Cj hinges without mirror holes? I assume they are stainless powder coated black? Also do they have bushings of some sort?
Your doors are looking good!

 

[P Bleskey]

Been getting the components together to do a door build myself. Tell me, where did you get your Cj hinges without mirror holes? I assume they are stainless powder coated black? Also do they have bushings of some sort?
Your doors are looking good!

Didn’t see your post on parts!Thanks!

 

[Jeepish]

looks legit, waterproof. They use it for bathroom doors and wall partitions, so they can hose them down.

Started working on my bathroom partition Roxor doors today. I measured the hood hinges and figured out that the bolt holes line up with the factory door hinge holes. Found a set of hood hinges on amazon for $35. Had a phenolic toilet partition door left on a job and it took me about 20 minutes to make the first one. The phenolic is 3/4” which is perfect. It leaves 1/4” for weatherstripping. Just need to decide on paddle latch or slam latch. Will probably paint them black but the phenolic is hard as a rock and very durable.

 

[Peder53]

CJ5 hood hinges?

 

[Jeepish]

CJ5 hood hinges?

Yea.
Crown Automotive RT34095 Hood Hinge https://www.amazon.com/dp/B00ZZAIFWK/ref=cm_sw_r_cp_api_i_ntMvCb9F88YG3