Solid questions here! Let's go one at a time:
What gave you the idea to use aviation materials?
Well, they're not just aviation
materials. Carbon and wood composites show up in diverse places...cycling, kayaks, canoes, larger watercraft, paddles, surfboards, skateboards, and yes: aircraft. Anywhere that a high strength-to-weight ratio is needed a carbon/wood composite can be a viable choice.
Or are you just that f***ing smart?
That all depends on who you ask.
What kind of resin would you use and what would you use to seal the bushings and such?
Bushings: Which ones are we talking about, here? The through-bolt sleeves I spoke of? I may not even need to include those. We'll see when the design starts to develop.
Resin: I haven't decided yet, honestly...I need to do a bit more research on what resin and fiber wraps will work best. Suggestions are most welcome if you're knowledgeable about such things.
Upon some extensive thought on this subject, I have came to the realization: Why not just buy some f***ing safari doors and wrap them in canvas?
Very, very, very
smart question...and the answer is: factory mirrors and factory hinges. I want a factory mirror in the factory mirror location, d*** it. The hard part of these doors isn't the skins, though...it's the framework. Once the framework is constructed it could be skinned with anything. I've thought more than once about canvas to match Greta's deck cover. Depending on where we go with the idea I may do this down the road. Incidentally, I'm thinking that I'll use 3M 5200 to attach the aluminum door skins...I've held transducers onto boat hulls with that stuff and drug them through the water at 75 MPH, so it should work here as well. No visible fasteners! Party! Bonus!
Don't mean to undermine your ideas, just sayin... You want your Jeep to be practical right?
Undermine? Questioning an idea is not undermining it; rather, it is giving it a chance to evolve. To that end: practicality is the major concern here and the framework is the difficult part. Thus, I'm focusing most of my efforts on that particular piece. I'm making it from wood because - through my father's expertise - I have several thousand dollars of woodworking tools and sixty-plus years of knowledge at my disposal ...taken together, those are a powerful argument.
Coincidentally, your mention of aircraft materials brings up another potential candidate for the frame material: plywood! Some rough figuring showed us that a skeletonized plywood/carbon laminate would be stable, lightweight, incredibly strong and much, much faster to fabricate than a Sitka frame. It would also cost less as I have a local source for marine and aviation plywood. Using plywood would, furthermore, allow me to sandwich carbon layers between
wood layers...and this would pretty much end our structural rigidity concerns.
So: the framework is the hard part and it can be skinned with anything. Why aluminum?
1. I have a local source for at-cost aluminum.
2. I work with CAD programs for a living so I can do a template of the door skins that I want and...
3. ...have a machine shop water-jet them to whatever shape I wish.
4. If you look at your factory doors you'll start to see why I want .125 aluminum on the outer layer.
Great series of questions all around, man...you guys are really helping me think through this process. Now the only real decision is if I get enough material to make more than one set of doors in the hopes that someone will buy them and help me offset my cost.