With the big oval part of the boot inside the door and the depth of the flare inside the narrowest part of the boot grooves, it sits there firmly. A this is how it looks when all in place. Can also just make out one of the plugs in the cavity inside the kick panel area once it has passed right through the A pillar. To remove the door I simply unplug from there and pull the boot through followed by the plugs and only takes a minute or so.


Doing what I can on the windscreen trim. The windscreen is 220mm-9" wider than stock so each side has to extend half of that. No height change as the whole windscreen frame was lowered instead by sectioning the cowl 50mm-2". The defrost louver lengthening finished. This is all you will see from the inside of the cab.


Enough airflow to work the defrost from the longer stock louver. The mounting holes were welded up and moved and re-punched to be even where needed. Now the door modifications are completed, I am stripping the doors right down and removing the hinges so I can spray the inside with a zinc coating. I drill a couple of small holes through the inner door skin and into the hinge so I can put them right back in the same spot. Each hinge was drilled differently so I know from where they came. When putting the hinge back, just line up the holes and screw it down.


Played around seeing if I could use the stock door check strap with the bar going into the A pillar instead of the door, to avoid the one piece windows, but just couldn't get it to work that way. So I'm going the same way as many Jeeps have. Going to start by welding this heavier gauge angle inside the door and A pillar where mounts will be fixed. Angle plug welded into position inside the door. This is just to make sure the screws don't get pulled through should the door be caught by a gust of wind or let go when parked on a side slope!


Ground down the welds and pilot holes drilled. Bought some stainless steel footman loops and using an old leather belt for mock up.