oh boy....going downhill again....
I would think with both of those it's probably similar thickness to just a regular door.
If you can get your hands on just the outside sheet metal piece, you have a workable solution.
I don't really see the door insert as a hard part to fabricate. The top on the other hand....ick.
The bolt on JK8 kit also retained the factory B-pillar where the current weld on kit replaces it. I wish I would have had this idea last year so I could have looked more carefully!
Depending or not if you wanted to be able to convert back and forth. I imagine you could talk to a company that makes a corner protector into make a longer version to cover the factory rear door opening?
I'm almost thinking that making the replacement top out of aluminum would be the easiest way to get to a prototype? Fiberglass is probably going to need a mold. Perhaps two 2-door tops could be grafted together with a modified B-pillar interface? The 4-door B-pillar does complicate things a little bit, anyone have a detail pic of that area?
Nope, no boat builders here. I know a few river jet boat fabricators up north.....
I do have to wonder if fiberglass is the best answer? I think an aluminum top if properly fabricated could be VERY cool. The JK is pretty boxy....but also doesn't really have a straight panel on it. Aluminum with a double wall top for insulation and the inside sprayed with a bed liner material could be interesting......
I suspect the top could be hand carved out of foam......or cnc machined if you had the means/cad data. Then that used for a composite mold plug or whatever.
Carbon fiber/kevlar/honeycomb composite anyone?
I think a few companies are making tops now.
AT for their habitat
Wild Boar for their fast back
You could ask them about their fabrication process.
Perhaps have a chat about your idea, the door infill panel and roof, with jscherb, who's already on this, and the Jeep forum.
His idea's, prototyping, testing and manufacturing are great, and he may be able to offer help, advice etc.
Just a thought!