Dave's la(te)st buggy build...

Fantastic day today! :woohoo:

 

Back to the door cards...

 

I worked out where the handle was going to fit and it coincided nicely with a round bump on the inner door skin, so I drilled a hole to take the hook bit on the end of the door handle

 

And then made a bracket to take the self-tapping screw that holds the handle in place (on a stock door too)

 

Then when I was happy with the alignment and fit of the cardboard template (that was made off the other half-door) I transferred the shape to the aluminium chequer plate...

 

And then drilled some starting holes and cut it out with a jigsaw...

 

Another test fit...

 

So this bit needs to fold over the top of the half door edge and look like a step (even though the door opens )

 

I then marked the door 'card' and drilled it with a DeWalt 12mm Extreme Bit,... it makes itself it's own pilot hole and then cuts the main hole. I've been using these for a few years, and figured if I was careful it would make a nice hole to fit a self tapping screw in, and would also skim the chequers off flat to let the screw head sit straight Chuffed with that, it worked really well!

 

Ahh... it's not going to fit in my little Clarke bender, as it's an odd shape What to do?... Yup, put the kettle on and have a think...

That worked! I thought back to how I'd bent the bonnet skin to make the LED light bar pod...

 

An offcut of 4"x2" rectangular box that had been cut in half for a door top, screwed to a piece of offcut 4"x4" fence post...

 

Clamp it to a work horse... Umm, it's going to move when I try and bend it?........ Go and fetch Mrs. Jones, to sit on the other end! :laugh: No photos allowed, Sorry!

 

Et Voila! :woohoo:

 

Nice looking "step" - there's only two screws in it so far, it will sit flat when it's finally attached...

 

And there's the handle neatly placed just in front of the seat base within easy reach from the inside and the outside!

 

Chuffed with how that's turned out! Making the passenger side one will be easier on Wednesday

Just need to order a box of self-tapping screws

I haven't attached this one fully yet, as I need to patch the remote mirror wiring I inadvertently cut off when making the half-door, and which James J999PRE has recently sent me the loom to replace it

Time for a shower and a beer then?! :woohoo:

Stay Safe Folks!  

at last... a jimny door where your knee doesnt bang sticky out junk!

Seriously though, it is looking very good Dave

Thanks Riccy, that's a real compliment from a modder of your calibre!

Hope to be back 'laning with you "soon"... 

Nice work Dave 

Soeley wrote: Nice work Dave 

Why thank you kind sir  

This is making me want to have another look at relocating the window switches away from my knee. Good work!