JaysZ Posted May 10, 2006 Share Posted May 10, 2006 I'm gutting the doors and I'd like to cut along this red line and plan on using lexan windows. Would the door remain structurally sound? I believe there is a door bar in it, if I were to remove that as well, would it still be rigid enough then? I just dont want the door to flex and wobble enough to come loose from the door latch. also, assuming all is well to go ahead and cut, would you guys recommend using a Sawzall or an angle grinder with a cutoff wheel? thanks in advance! hope to tackle this by the weekend. Quote Link to comment Share on other sites More sharing options...
Synlubes Posted May 10, 2006 Share Posted May 10, 2006 I'm gutting the doors and I'd like to cut along this red line and plan on using lexan windows. Would the door remain structurally sound? I believe there is a door bar in it' date=' if I were to remove that as well, would it still be rigid enough then? I just dont want the door to flex and wobble enough to come loose from the door latch. also, assuming all is well to go ahead and cut, would you guys recommend using a Sawzall or an angle grinder with a cutoff wheel? thanks in advance! hope to tackle this by the weekend. [img']http://i1.tinypic.com/xmtk6b.gif[/img] You can see that there is a boss (for lack of a better word) about 2" in all the way around the door. (some of your line is on it) I would only remove the inner part leaving the boss all around the door for strength. I would also leave the door bar in place. Get a short sawzall blade and take your time cutting. Find some small "c" channeled molding to trim it out when you done so you wont get cut by the sharp edges left on the door. Don’t know if it will pass a vehicle inspection in your state, you might want to check before you cut. Quote Link to comment Share on other sites More sharing options...
Clifton Posted May 10, 2006 Share Posted May 10, 2006 Is this a race car? If so I would cut the brace out too if there are door bars. I have fiberglass doors on my 71 that are cut out the way you have lined. They have some flex, I'm sure alot more than a gutted steel door and are fine. I don't run windows though. Quote Link to comment Share on other sites More sharing options...
JaysZ Posted May 11, 2006 Author Share Posted May 11, 2006 well, assuming i have the funds, the car will primarily be sorted for the track, but i hope to take it out on the street every now and then as well. here are some updates: the tools i used the sheetmetal i cut the final product the leftovers (its for sale if anyone is interested) now the door shuts nice and firm with a solid thunk! Quote Link to comment Share on other sites More sharing options...
evildky Posted May 11, 2006 Share Posted May 11, 2006 you might want to get the door bars out if your serious about weight, you'd be amazed how heavy they are, they are tricky to remove but if your going on a hardcore dieat it's a must Quote Link to comment Share on other sites More sharing options...
JaysZ Posted May 11, 2006 Author Share Posted May 11, 2006 would the door flex too much during opening and closing if i took them out? i see the 3 bolts holding the inner side in, how about outer edge? is it bolted in or welded in? Quote Link to comment Share on other sites More sharing options...
Guest ON3GO Posted May 11, 2006 Share Posted May 11, 2006 you have to cut it out. i would have left more medal then you cut out, even if your running the lexan windows. mike Quote Link to comment Share on other sites More sharing options...
OlderThanMe Posted May 11, 2006 Share Posted May 11, 2006 check this thread...: http://forums.hybridz.org/showthread.php?t=109769&highlight=lightened+cut+door Quote Link to comment Share on other sites More sharing options...
JaysZ Posted May 11, 2006 Author Share Posted May 11, 2006 that looks awesome! Quote Link to comment Share on other sites More sharing options...
bjhines Posted May 13, 2006 Share Posted May 13, 2006 as long as you use keep the edge profile height (thickness) of the door intact.. you will have a sturdy door.. some of the early 240Z doors had no side impact bar... you can remove the bar without causing any problems... except less crash protection... Quote Link to comment Share on other sites More sharing options...
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