Metal door repair -
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post #1 of 3 Old 11-29-2005, 09:08 AM Thread Starter
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1995 YJ Wrangler 
Join Date: Aug 2005
Location: Wickenburg AZ
Posts: 93
Metal door repair

I could use some ideas...
My 1979 factory metal doors with rollup windows have a stress crack/fracture in the metal. The crack on the inside is nearly 2" long and only about 1/2" on the outside. This crack is on the window side of the wing-pillar going downward. The metal is very thin and this is likely the problem. I have thought of just screwing a small aluminum angle to the door, extending well past the crack in both directions. Any ideas would be much appreciated.
Also is there a trick to removing the door-pannel that I should know about.
Thanks for the help.

1995 Wrangler SE, 4.0L HO, 5sp.
31" BFG Mud TA, Posi-Lok
5/8" greasable boomerang shackles
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Switched from CJ's after 20+ years!
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post #2 of 3 Old 11-29-2005, 12:42 PM
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1979 CJ7 
Join Date: Oct 2005
Location: Dayton, Ohio
Posts: 1,826
The crack has hit us all I have welded mine and redone them and even had a spare set of doors. Over the 26 years of having my Jeep the doors are getting bad and they are a pain to work on. There was a write up somewhere where they cut a piece off of another car door that fit the Jeep door, I don't have it anymore you might search the net on that one. I thought about YJ doors and just putting the door pin on the tub, but I found a set of fiberglass doors at a swap meet. I don't have them ready to go on yet, but JC Whitney has all of the door and window seals in a kit if you are looking for that stuff.
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post #3 of 3 Old 11-29-2005, 03:04 PM
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2002 TJ Wrangler 
Join Date: Sep 2005
Location: Manchester MI
Posts: 110
to stop the crack drill a hole thru the end of the crack
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