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#1 |
Its lookin' like a Blazer!
Join Date: Aug 2003
Location: Gods Country, KY
Posts: 1,773
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How to turn a Truck door into a Blazer door
I'm not a professional and I'm sure most of you already know all this. This is for the few that don't. If anyone has any pointers or helpful comments, post up. Actually jamie72 showed me how to do this several years ago so I thank him for this tidbit of info.
Its a pretty easy thing to do. The hardest thing to do is make yourself cut up a set of nice truck doors, lol. You only need a few tools. I used a reciprocating saw, die grinder with a cut-off wheel, hand grinder, and a drill with a 1/8" bit. Don't forget the imortant safety stuff, gloves, safety glasses, etc. I started off by taking a close look and some measurements on my factory doors. Then marked the truck doors where I wanted to cut. The first cut I made was on the lower part of frame that goes around the door window. I used a fine tooth long metal blade in the reciprocating saw. I layed the blade flat across the slot where the window comes up and cut straight across to the outside of the door. The next cut is at the top just above the vent wing assembly. Using the reciprocating saw I laid the blade against the ventwing window channel and cut up towards the top of the door. With those two cuts you have the major part removed. The next cuts I used the cut-off wheel. Right above the ventwing there is a flat spot. I had to make two cuts on this part of the door. The first part I cut off is the edge sticking up to the outside of the door. I held the cut-off wheel upside down and basically level to the flat spot above the ventwing. Making a slight cut all the way across the surface I just let the wheel work with a back and forth movement and it left a nice level cut. The last cut is toward the inside of the door above the ventwing just opposite the previous cut. Its just a small wedge you have to cut out for the plastic cover to fit on top. Where the door breaks over at the top above the ventwing, measure back about 3/8" to a half inch on the side and mark it. If you look on the inside of the window channel you'll see kind of a upside down horseshoe. The cut is going to graze the outer part of the horseshoe on the inside door side.I used a marker to mark the metal above the horseshoe edge. I used the cut-off wheel to cut this wedge out of the top of the door and it worked great. I slid on the cap/cover and it fit perfectly. I used a 1/8" bit to drill the holes for the two screws to hold the cap on. So just after 4 cuts and two holes drilled I have a real nice Blazer door. I'm going to go a few steps further than the factory did. I noticed on the original doors that those cut seams at the top of the door had come apart. I plan on grinding the third cut down a little bit and using the mig to weld it up. I'll grind it down and after some primer and paint it'll be good to go. If my descriptions of where to cut and how pay close attention to the pics, you'll see what I'm trying to describe ![]() |
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#5 | |
Its lookin' like a Blazer!
Join Date: Aug 2003
Location: Gods Country, KY
Posts: 1,773
|
Re: How to turn a Truck door into a Blazer door
Quote:
Thanks for the compliments fellas, I knew someone would find this handy. It'll be even more helpful when I get to complete what Huck just talked about, lol. |
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#6 |
Registered User
Join Date: Oct 2003
Location: Central Vermont
Posts: 8,538
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Re: How to turn a Truck door into a Blazer door
Those be the ones.
Nice thread Big J. |
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#7 |
Its lookin' like a Blazer!
Join Date: Aug 2003
Location: Gods Country, KY
Posts: 1,773
|
Re: How to turn a Truck door into a Blazer door
I finished up the doors. I still have to do some sand blasting and painting to do but the plate is welded on and the catch attatched. One of the plates was in need of some repair. The door rusted out behind it and messed it up a bit. It was nothing that couldn't be fixed. Be sure to take these pieces off your doors before tossing them. Don't forget to measure the placement of the catch on your door. It could be different on every door. Mine was 3 1/16" to the first hole from the top of the door down.
Last edited by Big J; 01-16-2008 at 03:44 AM. |
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#8 |
Post Whore
![]() Join Date: Feb 2000
Location: Rose Hill, KS, USA
Posts: 12,683
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Re: How to turn a Truck door into a Blazer door
I hadn't noticed that extra plate at the lock mechanism location - this thread is great!
__________________
1970 Blazer with a 400 sbc and 4" lift 1980 Pontiac Trans Am, 455 Oldsmobile 2012 Kawasaki Concours 14 |
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#9 |
Its lookin' like a Blazer!
Join Date: Aug 2003
Location: Gods Country, KY
Posts: 1,773
|
Re: How to turn a Truck door into a Blazer door
OK heres some more info. and pics. I'm adding a quicky how to on some door hinges. Its the way I do it, may not be the best way but I got it done
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#10 |
Its lookin' like a Blazer!
Join Date: Aug 2003
Location: Gods Country, KY
Posts: 1,773
|
Re: How to turn a Truck door into a Blazer door
and more pics. I'll include one of a bent hinge that refused to come apart. Even after a 5lb. sledge, lol. So thats how to turn a truck door into a blazer door and rebuild a hinge.
Good Luck! |
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#11 | |
Its lookin' like a Blazer!
Join Date: Aug 2003
Location: Gods Country, KY
Posts: 1,773
|
Re: How to turn a Truck door into a Blazer door
Quote:
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