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Discussion Starter · #1 ·
Has anyone made their own door panels?

In my ongoing quest for Jeep parts on the cheap, I’ve secured a pair of TJ full doors for next to nothing. As expected, they need a little TLC but thankfully are not rusted out. With the exception of one lock cylinder and both interior door panels, they’re complete.

New replacement door panels are ridiculously overpriced, so I’m looking into making a set. Are there any design requirements or pitfalls to avoid in order to make a decent fitting door panel for a TJ? Given that I have plenty of aluminum and stainless sheet available, I’m leaning more toward making new door panels from metal. Good? Bad? Am I asking for problems?
 
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