AndyR

NOTE: Parts List almost finalized: Attached is the 'work in progress' parte list. I will post a finalized list when project is complete. You will have to modify the interior and exterior Trim codes to match your JK

A while back I decided (in a moment of surplus $$) to add OEM half doors to my Unlimited. After searching for a while, it became clear that:

a) Real OEM half doors were not available 'off the shelf'
b) No 3rd party was making a full half door kit
c) Nobody had taken the plunge and built half doors from parts
d) I needed my head examining

So....off to my friendly parts guy. The result was two loads-o-parts:

The Fronts:


The Rears:


Now the instructions:

Before doing any assembly, spread out all the parts, identify, cross-check against parts list and group into piles (front & rear, then left & right) - you now have 4 piles-o-parts. This will take some time, during which you will hear phrases Jeepers have uttered for decades - e.g. Holy C**p, where does all this go etc. (oh yeah, the FSM is useless for this project). For each step, you'll need to find the correct parts and the associated mounting hardware. If you can't do this, then this project isn't for you.

1) Mount hinges to door loosely
2) Mount latch mechansim in door
3) Adjust hinges to body latch striker and center door in surround (bottom / sides) - remove door & latch mechanism
4) Torque/loctite door hinges to spec
5) Assemble, Latch, Presenter, Bell crank and 4 connecting rods

Fully assembled latch/handle


Latch/presenter detail 1:



Latch/presenter detail 2:


Interior latch pull detail 3:


6) Mount door - makes it easier to work on
7) Get lock cylinder keyed. Assemble cylinder mechanism and mount on door. Has to be in place before latch mechanism is mounted.
8) Install compete latch mechanism (latch, presenter, crank, rods)
9) Install exterior door handle
10) Install interior door pull - connect to rods from latch mechanism (uses two plastic square nut inserts)

Assembled latch/handle installed into door shell:



12) Install weather strip
13) Install wiring harness

Update: 1st Snafu hit.

The electrical plugs on the half doors do not match those on thd body. The half door plugs have two pins, the full door ones have 10, 8 of which are used (I only need the purple & black/white wire).

14) Install footmanloop
15) Install Mirror
16) Install Door trim panel

Interior trim installed:


17) Install Interior door handle caps (if needed)
18) Install Window Guides
19) Install Window

From the inside:

From the outside:


20) Repeat for 3 more doors

Now...disassemble, take to paintshop, paint, reassemble, go wheelin'.

Andy

Caboose

woah woha woaaaaaah dude...

How where..how and how much?

AndyR

Where: From your local Mopar Parts deler.
How Much: Price will be significantly impacted by how much under 'list' you can get the parts for.

Here's the list price for the 'major' components

Door Shell $790 x4
Window $277 x4
Mirror $97 x2
Trim Panel $116 x4
Latch+support $85 x4
Harness $21 x4
Hinge $43 x8
Handle inside $25 x4
Handle outside $37 x4
Cylinder Lock $33 x2
Weather Strip $52 x4

This is about $6200. Then round it up to $7000 for all the other 'little bits'

Andy

woolf

$7000 FOR HALF DOORS!!!!!! ARE YOU CRAZY? Looks great, and awesome writeup, but for that price you could buy a nice TJ with half doors and then just drive that around when you feel like you need the halfies.

WRAITHYJEEP

he self admitted to being possibly crazy
"I needed my head examining "
also look where he is from "south of disorder"

list of part numbers would really top off this post for the next crazy guy.

well that is a project that i can admire.
sure beats workin on model cars on a rainy sunday afternoon

mikeyfl

to you for diving head first into that project!

are you going to supply part #s with your final write up? either way awesome job.

AndyR

Yep. I had a nice TJ with half doors, the problem was that it was missing the two rear doors

Andy

AndyR

I've 'attached' the parts current parts list to the 1st post.
NOTE: THIS IS NOT THE FINAL LIST. Caveat Emptor.

Andy

bsack

$1700+ a door!!!!!I think ill slum it with the full doors til something cheaper comes along, but damn they look nice

Caboose

With all due respect... i must say..

FUCK THAT!


ill just take my damn doors off.. ill wait till the half doors hit $1-2k for all of em or when they offer dual doors just like the dual top deal

They look really nice though, but 7 grand can go long ways in other stuff