I know this is a old post, but figured for future readers I'll add my 2 cents. I did this to my zj already, and really love it! I wanna do it to my xj, but its the nicest an newest thing I own, so I cannot bring myself to do it yet! lol! I had to remove my carpet in my zj after the first summer. Also another issue is remembering to lift the doors when you shut them (mostly passengers) or else it hits just on the edge of the hole an ruins you door ability to retain its latch after so many slams...I'm on my second passenger door now... lol
What do you guys think about drilling the top hinge for a removable bolt, but just unbolting the bottom hinge at the door? The way I've thought it through the door won't be as likely to sag since the stock hinge is holding on at the bottom. The downside is it'll take longer to put on and take off.
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At first I just popped out the door pins and used 5/16" bolts with the stock bushings. Worked fine, but the doors sagged pretty bad over time due to the bushings wearing out. It was also a huge pain to pull the bolts out each time and then line them up to put back in while holding an 80 lb door.
This post shows what I've done now pretty much. Take the hinge off the door, cut the bottom half off, drill out the top hole to 3/8" and weld a 3/8" bolt in there. Take the bushings out of the body side of the hinge and the bolt fits perfect in there. So now you bolt the hinge back up and taking off the doors is as easy as disconnecting wires and lifting the door off. The doors close much better now too, line up like stock (unless you come down hard on the a-pillar and tweak it...)
Oh, I think this is like the 4th time I've posted this same thing in this thread. People keep asking the same damn questions instead of just reading the thread...
How are the bushings going to stay in there? My stock bushings were pretty much destroyed and eventually fell out. Take the doors off a few times and any bushing will fall out of there. I haven't had problems with mine squeaking or anything without bushings.
Hey decorn i like the idea and plan to do the same however the holes on the door jam side are larger than 3/8 and cant find 7/16 bolts anywhere, i dont really want to drill them out to 1/2 inch, i think that would weaken them too much, any suggestions?