Blender, My LX450/FZJ80 + FJ45esk + GM + Land Rover crazy concoction

Option 3 - It's functional around the mirror, and looks like a design feature. The other two look like the rear of the cab doesn't line up with the front of the cab, so the door tapers to suit. Option 2 is worse than Option 1 at this.

Thanks for the thread, I've been watching this since the start and learnt a lot; mostly tool envy.
 

Metcalf

Expedition Leader
Option 3 - It's functional around the mirror, and looks like a design feature. The other two look like the rear of the cab doesn't line up with the front of the cab, so the door tapers to suit. Option 2 is worse than Option 1 at this.

Thanks for the thread, I've been watching this since the start and learnt a lot; mostly tool envy.
Thank you for the input. Option 3 is also my current favorite ( till I change my mind in two minutes ). I like that the angled section basically matches the rear of the front fender and the kick panel vent. I think option 3 will also be the only one that I can have a dual way sliding window. The others would only allow the window to slide in the rear section.

P.S. You know most of my tools are Harbor Freight right?
 

NCFJ

Adventurer
Snap On does not come with talent, that sir is something you either have or you don't. You have it in spades.

Ever notice how many Snap On tool boxes are for sale on CL at any one time? Most of the time they are priced at right about what the guy owes the Snap On man.
 

Metcalf

Expedition Leader
Tonight I decided on the door design and moved forward....







This version ended up being the best option for a few window based items. With this shape of the window, with the long bottom flat, I can have dual way slider. That slider will be able to open about 9" on either the front or the back of the window, or a combination.

The flat on the door is PLENTY long for my arm.

Now to model up this 2pc door split idea and then turn the templates into aluminum!
 

Metcalf

Expedition Leader






The #LX45 2pc door mockup is done. Hopefully my sheet of aluminum is ready tomorrow so I can turn this into metal! Overall I am very happy with how the concept turned out so far. I will be bonding the upper door sheets together with 3M panel bond adhesive along with clamping them with the window frame. Hopefully I can flush mount some tapered head fasteners into the door skin and hide the upper ones behind a detail panel. I will be using some neat cast aluminum knobs I fount on mcmaster to clamp the upper in place. Don't worry, I also have a neat plan for an armrest/handle that will work with or without the upper door.....
 

Metcalf

Expedition Leader
Good day....



One more view of the mock up door system from outside. I don't open up the big door too often this time of year because 'winter'. It was really nice to be able to get more than a few feet away....



I had to open the door to bring in some nice fresh sheets of aluminum! This is 3/16 thick 5052-H32 that I will be building the doors out of.



I took the mock up door apart to use for templates. This sure made things easy. Don't forget to account for the saw kerf during the layout. I wanted to cut the upper and lower door in one piece and THEN seperate them. That way the cut would match up well top to bottom.



I have been looking for a better way to make LONG cuts in thicker aluminum sheet for a bit now. After much google-fu and Youtube this is where I stopped. While they aren't cheap, these blades work AMAZING! I was able to use a section of thick aluminum angle as a fence for the saw. This blade is specifically for aluminum according to the package. It cuts this 3/16" plate like BUTTER. This is what I used where ever possible. This method is so much cleaner and faster than anything else I have done.



This is how I handled inside corners. I pilot drilled the corner with a small drill bit. I would run the big saw as close as possible. I then used a small body saw to finish the cut. All it takes is a little file work to clean up at the end.



Here is the roughed in lower door. I will still be adding some details, but the hinges hinge and the latch latches.



Upper door resting in its future home.



Seam between the upper and lower.....not too bad for just a guy in his garage I don't think.



I also got the inner 'tongue' panel mostly cut out.

Next I need to cut the window hole in the top and tongue panel. Those two parts will be glued together with some 3M Panel Bond once finished ( which is still in the mail....ugh). I also need to build the arm rest bracket that will also have the interior door handle and perhaps a forward mounted door latch release. Still a decent bit of detail stuff....
 

Metcalf

Expedition Leader
Mostly just repeats tonight...



Passenger side door panels are all cut out.



I also made the passenger side versions of the door hinges.

Shop tip....



I tried these Dewalt Impact-ready drill-tap-countersink bits for the first time tonight. I did the 6mm threads for the TJ mirror mounting hardware in the hinges. These things work fantastic. They are designed to be used with a 1/4" impact driver ONLY. You don't want to use them in a powerful drill. They use the impact action to break and clear the chips away. I have to do a LOT of small tapped holes in the bed frame for the side panels. My hope is that these things really speed up the process.
 
I only made it through the first page before jumping in here with a question, sorry if it's been covered but...can you give us a 1 1/2 year review on that Klutch 220? I've been eyeing that and an Everlast unit and it looks like you've been doing a ton of fab work so your input would be greatly appreciated. Thanks!