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Thread: 2013 JKU Tube/Trail Door Build

  1. #1
    Molon Labe USMC Wrangler's Avatar
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    Default 2013 JKU Tube/Trail Door Build

    A buddy and I are taking a welding class and we get to pick our projects. I chose trail doors of course! All materials are already on hand and bending started today.

    2013 Jeep Wrangler JKU tubular trail door material list

    Materials
    1" ID, schedule 40, black pipe - total length = 51 feet
    1/2" ID,schedule 40, black pipe - total length = 1 foot, 6 inches
    1/4" plate, 12" x 12" - total pieces this size = 4 (used for latches to attach to each door)
    Already have 1/4" plate, 6" x 6" - total pieces this size = 2 (used for side view mirror plates on two front doors)
    3/8"-16 x 3 3/4" hex head bolt, stainless steel 18/8 - total needed = 8 (two per door for hinges)
    3/8"-16 lock nuts, stainless steel 18/8 - total needed = 8 (two per door for hinges)
    3/8" flat washers, stainless steel 18/8 - total needed = 16 (four per door for hinges)
    #10-24 machine screw, Phillips pan head, stainless steel 18/8 - total needed = 16 (four per door latch assembly)
    #10-24 lock nuts, stainless steel 18/8 - total needed = 16 (four per door latch assembly)
    #10 flat washers, stainless steel 18/8 - total needed = 32 (eight per door latch assembly)

    Front Door
    Top rail 38"
    Center rail 38"
    Bottom rail 85"
    Support angle rail 12"
    173" per front door = 14.42 feet or 28.84 feet for both front doors (so get 30 feet)

    Rear Door
    Top rail 30"
    Center rail 25"
    Bottom rail 66"
    121" per rear door = 10.08 feet or 20.16 feet for both front doors (so get 21 feet)

    Door Latches
    One pair Rugged Ridge latches - need two sets (one pair on hand now)
    http://smile.amazon.com/gp/product/B...?ie=UTF8&psc=1

    Door Limiter Straps
    Front
    http://www.jeep4x4center.com/warrior...-war90798.html
    Rear
    http://www.jeep4x4center.com/warrior...-war90799.html

    Mirrors
    http://www.jeep4x4center.com/rugged-...-11025-12.html

    Bed-liner/Paint
    Self etching rattle can primer
    Rattle can bed liner, black


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    Last edited by USMC Wrangler; 02-02-2015 at 08:27.

  2. #2
    Molon Labe USMC Wrangler's Avatar
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    I am using the cheapo Harbor Freight pipe bender which was cost effective but is frustrating at times. The biggest frustration is not having a guide showing me the angle the piece is bent. Another is that the two rollers are a "one size fits all" die roller, which can lead to divots on tight bends. The middle, bending die gets wedged on the pipe, but that ended up being good to ensure the material is in the same spot between test fits. But anyway...

    ImageUploadedByTapatalk1422850411.983308.jpg

    I removed the doors and made a template for the front and back with poster board. It's hard to see in the pictures my total layout but it works in person.

    Front
    ImageUploadedByTapatalk1422850564.140697.jpg

    Back
    ImageUploadedByTapatalk1422850594.030513.jpg

    This is the style I decided on after reading many reviews and studying many Google images...
    ImageUploadedByTapatalk1422850613.731453.jpg

    First bend on the first front door
    ImageUploadedByTapatalk1422850659.117039.jpg

    I couldn't figure out how to set the pipe in the exact position to get the second bend in the right place. Luckily I went "too far" so I cut the excess from the middle and will of course weld them together. I duplicated the "mistake" on the other front door.
    ImageUploadedByTapatalk1422850791.395078.jpg

    I finished the lower sections for both front doors and started on the lower sections for both rear doors. I hope to finish all the bends, get the other pieces cut and then start tacking up tomorrow. My goal is to have these done and painted by the end of the month! More updates with pics to follow!


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  3. #3
    Senior Member ETSubchief's Avatar
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    Looks good.
    Bless those who serve beneath the deep, through lonely hours their vigi keep.
    May peace their mission ever be,
    Protect each one we ask of thee.
    Bless those at home who wait and pray, for their return by night or day.

  4. #4
    Member warthog_cj7's Avatar
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    It's easier to buy things.

    But to build yourself, even with learning issues, still takes the cake, as You built it and Learned something along the way.

    Keep the pics posting.
    Dan M.

    '85 CJ-7, 4.0L,T18,4.10s,35s,Fully locked,winch,cage

  5. #5
    Molon Labe USMC Wrangler's Avatar
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    Quote Originally Posted by warthog_cj7 View Post
    You built it and Learned something along the way.
    Absolutely. By the time I did the last bend on each of the rear doors, I had figured out how to lay the piece on the template and line up the center, bending die. I really was trying to get these lower sections all in one piece, which didn't work out this time. I was also shown how to "saddle" the ends of the pipe using a chop saw. It's just something I've never had to do. It's frustrating and fun at the same time. I should have some more pics soon...



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  6. #6
    Molon Labe USMC Wrangler's Avatar
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    Here are a couple shots from yesterday. The setup table was not square, that will be rectified by next week. I got the lower sections of both rear doors tacked up, but you may see that they don't quite match. I was running short on time so I quickly threw those tacks down. I'm sure I will end up breaking the take on at least one of the rear doors. The learning curve continues...

    Setting up to tack
    ImageUploadedByTapatalk1423016697.275306.jpg

    Tacked up for now
    ImageUploadedByTapatalk1423016724.261088.jpg

    I'll be ordering my own welder and torch setup soon. I only have access to that equipment at class right now.


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  7. #7
    Molon Labe USMC Wrangler's Avatar
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    My Lincoln Power Mig 210 MP and Victor torch setup were ordered today. They should ship early next week! Once those items arrive I expect to make progress a little faster. Right now I only have access to a welder at class, every two weeks.

  8. #8
    Molon Labe USMC Wrangler's Avatar
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    Well, just got the dreaded "backordered" email on the welder. Expected ship date is March 10th. So back to only making progress in class. Next class is 2/16, so I should have more updates then.

  9. #9
    Molon Labe USMC Wrangler's Avatar
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    Default 2013 JKU Tube/Trail Door Build

    Made some progress today. I did get to test fit the lowers of all four doors in the frame, on the Jeep. I'm really happy with the fit.

    Front lowers...
    ImageUploadedByTapatalk1424134783.487080.jpg

    All pieces cut for the rears and started cutting some of the angles.
    ImageUploadedByTapatalk1424134841.580217.jpgImageUploadedByTapatalk1424134856.443387.jpg

    Started some helmet "mods" too!
    ImageUploadedByTapatalk1424134936.338411.jpg

  10. #10
    Molon Labe USMC Wrangler's Avatar
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    I can't make it to class next week, so the instructor is opening the shop for me this Wednesday. I hope to have all four doors tacked up and ready to test fit to get the "hinge" locations marked/tacked. Pics to follow...

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