I did like this, Drone637.

I made a paper template that I used for marking and cutting out on both doors.


This is the door with the piece from the donor door that is cut exactly to fit. As you can see I have opened the folding in the edges.


The piece in place fasten with some spot welds. I have also folded back the outer panel over the inner panel.

Then I finshed up the welding and grinded it.


After some lead, sanding and zink I painted it with primer. That was about three hours work.

Kind regards from

Hannes

That looks good.  I noticed on my SJ-410 that with the older window felts water was able to get inside the door and was sloshing around.  I drilled a couple of holes in the bottom of the door to give the water a way to drain out to help stop it from rusting in the future.

Yes Drone637, drain holes in the doors are important especially when driving in the terrain. I have done this to make it look like stock. The oblong holes is original for that purpose. The small holes is for fastening of the rubber.

I'm comming back to you Jluck in a later post about the colored switches inside the cabin.


After some adjustments the door is in place.


This is how the jig looks like at this stage. As you can see the window frame is totaly rusted out. Also the window has a crack. I'm trying to get a used cheap frame with an unspoild window. To much job to fix it (even for me )

Kind regards from

Hannes

I didn't even notice the oblong holes down at the bottom.  Nice work!

I recently replaced my Windshield frame as well, the old one had been slid into a few trees by someone and broken off twice causing the windshield to be destroyed.  No idea how that could have happened. 

lets see some more.....`ya are not grounded are you? don't forget about the cabin switches too. thanks

I've really enjoyed following your build hope to see some more of your work.

  Kid's got skills.

Where have you gone Hannes?   I want to see more of your fine craftsmanship. Your thread has been quite educational.   thanks  c