I recently bought a 72 door, and was really impressed with how light it was, almost half as heavy as my 74. Noticed the 74 has a huge beam running the length of it for impact protection. But, I want lighter doors, as I will be doing a roll cage soon and don't need the extra 60 pounds on that side, and don't want to have to SLAM the door to close it. The older door closes with a gentle nudge. Would I be able to cut that beam out without harming the outside skin? It appears to be tack welded with 3 tacks front and back. It is multiple layers thick in the middle, then only folded to two layers and flat at the front and back where the tacks are. My other idea was maybe to cut the outer layers off and then drill 1" or larger holes throughout the last layer, but I am not sure I can do this without punching through into the outer skin. Any suggestions? Short of buying another 72 door (which I would like to do, but still need to get my 74 hardware to fit the other one, and don't have a welder yet to finish that project up.).
I know there isn't hardly any room to get in there, but the best way I can think of to remove it without messing up the skin of the door is grind down each weld until it breaks free. Real question to me is how would you get it out once you get it free from the door skin? I can't see any way short of cutting it in half inside the door and then trying to slip each half out. Personally, I don't think it's worth the trouble. I'd just find another door.
Jamie...good point that I didn't even think about...(removing the bar) My wife swears she will be buying me a welder for my birthday (July 31) so maybe I will cut the inside of both doors out and do the mods, then weld them back in I already have to cut out a chunk of my old 74 door to weld into my 72 so my 74 door handles will fit in it.
YUP! The one from the swap meet, I hope! Any idea how much those small oxy and acetylene tanks would run me, with regulators? I would have to look again, and hope they come as part of the kit, but I doubt it.
I don't have the other door, and the local yard didn't have any good ones. My door is straight. Also, I don't want to have to do the cutting out of the inner door panel to make my current handles fit like I am having to do to the early door. found bottles on e-bay new for about $100 each. I want small bottles, maybe 2' tall, I think they are 40 cf? Figured I could find used ones for much cheaper...will check the local welding shop.
try and take those bars out and your door wont be strait anymore!!! Trust me,Im a bodyman with over 22 years exp . The only way without killing the doors is to REMOVE the skin or try and cut the brace out through the inside(it aint gonna happen). Save yer pennys and get some doors or be prepared to do some major panel beating!!!
How about if I cut the entire inside panel out to remove the bar, then weld the panel back in? I am doing this to half the inner panel on the other door so the handle will bolt up. Are you saying that removing the bar will actually affect the shape of the door, or I will mess the door up while attempting to cut it out?
I think he means you might mess it up while cutting it out. I think cutting the inside panel out is a good idea, that way you don't have to get it perfect when you weld it back in as it will be hidden behind the door panel. I'd use a grinder and carefully grind down the areas where it is spot welded. It should break right free without damageing the outer skin. I guess it's just all in how much time vs. money you have. If you got the time and not much money, start cutting. Otherwise I would just find another door.
what Im saying is that there is not much room to cut it out and if you wanted to remove the whole thing at the factory welds you can (and will if you dont know what your doing) mess up the outer doorskin,the inner shell or both.I wouldnt worry about the added weight of the bars on anything other than a race car anyway.Its not worth the effort.Just my opinion but its your car and all I can ad is if you do go ahead with it just be carfull and dont rush or fight it.The more carefull you are the less work you have to do to fix things later
Cool, thanks for the encouragement and warnings. I wish I lived near Jamie...he would be able to find me an older door...and probably get it for $15
scott. i have a door you can have to practice on. door is no good any more. i just want to keep the window and tracks.
