How-To--> AE86 door weight reduction

[hvguy]

Starting weight - 55lbs
Ending weight - 22lbs

Tools Needed.

Angle grinder with 2 cutting wheels.
Jig Saw with metal blade
12mm socket
10mm socket
3/8" ratchet
2 inch extension
needle nose pliers
safety glasses
ear plugs
thick leather gloves.

First, remove your door by first removing the front fenders.

The hinges take a 12mm socket.

After removing the door- Remove the plastic inner lining.

Remove ALL of the 10mm bolts that are visible, EXCEPT THE DOOR HANDLE!! foo dont forget the 2 bolts that hold the window to the actuator


Remove the door stop located between the hinges to avoid cutting it.

Remove the linkages going to the door lock actuator.

BE SURE TO ROLL UP THE WINDOW BEFORE CUTTING OR DRILLING!!

Drill out the spot welds with a 1/2" drill bit


cut along the bottom of the door leaving a 3/4" gap between the seam to allow some rigidity.



after removing the sheet metal lining, Slide out the window and cut off the remaining metal.


Cut the door bar along the lines shown
BE CAREFUL NO TO CUT TOO DEEP TO WHERE THE BLADE CUTS THE OUTSIDE OF THE DOOR!!!
after cutting it, PULL HARD its glued in place =/


here is what you should have left


This is the door, entirely gutted


Cutting references


lock linkages


For those who want their window to stay up, start brainstorming.

I thought of using bailing wire aross the bottom, or putting a wooden stick and wedging it from the bottom of the door to the bottom of the window.
basically, get creative.

Questions? email meh motboy2@msn.com

[nt66]

i left the top of the inside frame so id still have a door handle

[hvguy]

=P why do that when you can reach back and pull the lever =D

I was thinking of leaving it... but I figured get as much weight out as possible.

[dr.occa]

guys just take all the fenders, doors off and make a lexan box car. you'll be like wonder woman and her "invisible" jet, but ugly. :D

[hvguy]

guys just take all the fenders, doors off and make a lexan box car. you'll be like wonder woman and her "invisible" jet, but ugly. :D

actually, If all goes as planned, Ill possibly make all my windows lexan, along with my hood and trunk.

but the hood will be hard to bend

so probably not since my engine bay is UGLY!!

[landslideATX]

we did this with my friends old hatch cause it was going to be a track bitch. i just rigged up some zip ties for a door handle like the falken fd i sat in the week before at a show they went to at spi.

[hvguy]

we did this with my friends old hatch cause it was going to be a track bitch. i just rigged up some zip ties for a door handle like the falken fd i sat in the week before at a show they went to at spi.

same here- I took the old linkage, hooked it up to the mech. and soldered a RED insulated piece of 10Ga. wire for a handle, and hung it with some bailing wire.

As for the window, I put a sheetmetal screw into the hollow door cavity to hold it up--




good luck charm

[landslideATX]

so with this set up how do you roll your window down?

[nt66]

you dont cause there is no window

[landslideATX]

his has a window though

[Overdrift]

you dont cause there is no window

windows are weeeeeeeeeeeaaaaaaaaakkkkkkkkkkkkkk

[hvguy]

it keeps the dust out temporarily, but I take it out when I go out

[dr.occa]

unfortunately my "weak" self likes nice things too. this is no longer nice sorry to say.

i had contemplated doing this but in my contemplations, i would have cut out the inside door but left tabs/peninsulas and used them for mounting points for a lexan inner panel.

keeps things nice and tasteful and still accomplishes the same thing.

[mr.momo]

you always seem to a amazes me orlando

[Overdrift]

I want to gut my convert doors.