3rd Gen 4Runner Tube Door Build

[NC994Run]

I've decided to build my own set of tube doors since nobody currently makes any. I'm going to use 2" by .120" wall HREW steel for the doors with home made latches. I got 40' of steel Friday and miscellaneous other parts for the latches/ speakers etc. I'm following Cubuff's design from TOF. Now onto the pics...
Car with tarp where doors used to be (about to rain)
http://i29.photobucket.com/albums/c298/4RUNITOVER/196.jpg

Mock-up of front doors
http://i29.photobucket.com/albums/c298/4RUNITOVER/197.jpg

Door latch parts
http://i29.photobucket.com/albums/c298/4RUNITOVER/199.jpg

1 of 4 10ft. pieces of steel
http://i29.photobucket.com/albums/c298/4RUNITOVER/200.jpg

It's going to take me a while to get these done (have exams soon). I don't have access to a welder until I get home, so for now I'm just trying to get the mock-ups perfect and the steel cut into the pieces I need.

[neliconcept]

yeah yeah!! cant wait

[RunnerUp]

oohh!! i cant wait either... subscribed!

[4runnerchevy]

I know you want to build it tough. The doors are only as strong as the hinges, especially without a door jamb. Is there a plan for the hinges, or when the door takes a hit, is it in your lap ? Sorry but too many places build from 2" and hook it to 1/8" door hinges.

Just my 2 pennies

[NC994Run]

I will be re-using the stock hinges, which should be beefy enough to take an impact. Besides, if I were to get hit from the side, my slider would take most of the impact first (given that it were not an overly lifted truck or semi)

[04 Rocko Taco]

Some people would say the 2" is to bif of a tube for tube doors, and I think beforehand, i would have agreed, but my bumper, sliders, and doors for my '84 are all made out of 1/75" DOM, and it grew on me quickly. Best of luck with these things! I cant wait to see the finished product!!

[BruceTS]

I like my hermetically sealed cab, besides it would be a PITA disconnecting the wiring each and every time....

[Mossyrocks]

I ran my tube doors along the bottom as well to take some stress off the hinges and latch. Might want to do that if your worried at all.

[NC994Run]

I like my hermetically sealed cab, besides it would be a PITA disconnecting the wiring each and every time....


The wiring is just 4 clips for the front doors (2 per side) and the rear is just 2(1 per side). Since they are just bunches of wires, its pretty easy to disconnect. It does take a little bit of time to get the doors off and on, but I've gotten it down to about 10 minutes to take off the drivers front and rear doors.



I ran my tube doors along the bottom as well to take some stress off the hinges and latch. Might want to do that if your worried at all.

I thought about doing this. Considering the tube doors will weigh less than the stock doors I'm not too worried about them being overstressed considering I'm re-using the stock hinges. Thank you for the idea though, I really like your tube doors.

[NC994Run]

I decided to change the design of the front door (top) to match the rear door
http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0567.jpg

I also picked up one a cheap miter saw and some steel blades to help with cutting angles

[NC994Run]

Finally got some time to work on these today ... started cutting up the steel. This is one of the rear doors
http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0569.jpg

[neliconcept]

you gonna notch the ends of the tubes?

[NC994Run]

I'm not sure what you mean by notching, but I plan on capping off the ends with something.

[Cebby]

He means notching the tubing on the ends that will be welded to each other. Notching (or coping) the tubes makes the joints nice and clean and when welded, nice and strong.

You canuse your chop saw and hopefully you have an angle grinder. Here's a couple articles/threads for chop saw notching:
http://www.offroadfabnet.com/forums/showthread.php?t=331&highlight=chop+tube+notching
http://www.offroadfabnet.com/forums/showthread.php?t=2709&highlight=chop+tube+notching

And an online helper: http://snip.awardspace.com/

[NC994Run]

Ok ok, I get what he means, I might notch them, I just don't want to lose too much length, but I doubt it will take too much off. It would definitely make it look a lot cleaner.

[NC994Run]

Just picked up a very lightly used welder today, should help the progress of the doors

[NC994Run]

Have had some time to work on these, hope to have them mostly done Wednesday evening

http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0570.jpg

[NC994Run]

got these pretty much done

Front door wasn't completely done at this point
http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0572.jpg

http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0573.jpg

Speaker Mounts
http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0576.jpg

[NC994Run]

Finally got some to work on these (summer job is in Montana)

Cut some 22 gauge sheet metal to cover where the speakers go and started painting

Pic of the door with sheet metal (will have painted pix up tomorrow)

http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0600.jpg

[Lee]

looks awesome man!

[NC994Run]

Painted pic (used Rustoleum semi-gloss)

http://i29.photobucket.com/albums/c298/4RUNITOVER/DSCN0602.jpg

[Mossyrocks]

Ive got speakers ready to go on mine as well. Along with some damn pockets.

[slosurfer]

:thumbup: Very cool!

[RunnerUp]

im lovin the progress!!