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brennanmetcalf brennanmetcalf

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Brennan Metcalf 

I cut some more big holes in big parts tonight for the doors on the #LX45. Now to figure out this panel adhesive bonding stuff to join them together. Then it will be time to add the pins and knobs. Still have a few more parts to make also. Overall I really like how this idea is coming together!

Cutting big holes in my #LX45 upper hard doors.....

Latch handle and strike plate on the passenger side #LX45 door.

I'm not sure if this is crazy or brilliant, but it worked WAY better than I thought it would. I turned the stock 2013 GM column shift cane into a floor shifter in the #LX45. This gives me the buttons for the tap shift and tow/haul. Ergonomically, I will admit it looks funny, but it actually puts the rap shift buttons in a nice natural location for the driver. It should be easy to make a boot to cover up the bottom. I still might play with the angles and rotation, but it ended up working better than I thought it would....

Replicating parts for the passenger side door on the #LX45. That is enough for today...

The first #LX45 door is roughed out in aluminum. These Diablo aluminum circular saw blades are magic. For long straight cuts this is the way to go! Now to sort through the detail stuff. I'm waiting on panel adhesive and a few other things....

Happiness is fresh clean sheets of aluminum and a new view of the #LX45 project with the door open....

The #LX45 2pc door mockup is done. Hopefully my sheet of aluminum is ready tomorrow so I can turn this into metal! Overall I am very happy with how the concept turned out so far. I will be bonding the upper door sheets together with 3M panel bond adhesive along with clamping them with the window frame. Hopefully I can flush mount some tapered head fasteners into the door skin and hide the upper ones behind a detail panel. I will be using some neat cast aluminum knobs I fount on mcmaster to clamp the upper in place. Don't worry, I also have a neat plan for an armrest/handle that will work with or without the upper door.....

Door decision made on the #lx45. Thank you for the input everyone. Now to mock up the 2pc door system.....

What door split line and window shape wins for the #LX45?

Mockup door is now working on the #LX45. Now to finalize the door split and see how that idea is gonna work out......

Door hinge number two on the #lx45 is done. Now I can do some final test fit on the door template. I also test fit the tj mirror.

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