Grand Wagoneer Doors
(Click on any picture for a larger view)

The doors are from an 85 Grand Wagoneer that was being parted out. This should have been a very straight forward project, but I tend to want to fix things that I see that need to be fixed so this (as most of my projects seem to do) got a bit more complicated as it went along. This is the process of installing and prepping the drivers side door, the passenger side door will follow shortly (hopefully within a few weeks).

Door first mounted, I had to increase the size of the wiring loom hole in the cab for the wiring loom protector to fit. Door first mounted, I wonder what a J-10 with full Grand Wagoneer woodgrain would look like? After removing the fake wood sticker from the top inside of the door, I was left with a sticky gooey mess to clean up.

This is the new wiring harness I made from the original pigtail cut at the door jam. Since this truck did not have power doors originally the entire wiring harness needs to be custom built and installed. Part way through removing the trim and woodgrain from the outside of the door. Inside of the door with the gooey mess cleaned up. Lots of holes where the door panel retainer and door handle were mounted.

After woodgrain removal, again lots of glue remains that needs to be cleaned up. Glue removed. There are big holes where the original electric mirror was mounted, and lots of little holes where the woodgrain border trim was riveted into the door. As many FSJ doors are, this one too had sheet metal cracks where the support brackets hold the inside and outside door skins together.

More sheet metal cracks, this one on the inside sheet metal is also common on FSJ's. Some of the holes that need to be fixed on the inside of the door. Here we are, ready to weld up the holes on teh outside of the door.

This was where the original GW power mirror mounted, there is a backing plate welded in at this point (yes my welding leaves some to be desired). This is one of the holes where the woodgrain trim was riveted to the door. This also needs to be filled. This is the crack on the inside top of the door after the initial weld bead was applied.

There used to be some holes here. I may not be a perfect welder, but I'm good enough I guess. This used to be a crack in the inner top sheet metal, again I guess my welding will suffice. There also used to be a hole here.

Outer skin, holes welded up and thin application of body filler to smoothe over where the holes were. Inside of door with holes welded up and again, a little body filler to smoothe over where the holes were. First primer coat complete.

Inside primed. Not necessary in the middle since I did not have to make any repairs, and the door panel covers this area anyway. Mostly re-assembled complete with custom ABS plastic door panel (waterproof). Mostly re-assembled, still needs mirror mounted.

Mostly re-assembled, still needs mirror mounted. Closeup of where there used to be a few holes. Closeup of where there used to be a few holes.

Completely re-assembled and mirror mounted. Completely re-assembled and mirror mounted.

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