King Julian
New Member
Here's how I fit the CE door cards onto my CC doors to match the dash. I'm not sure this is for everyone but it was the only way to do it properly, This is completely up to a vehicle vehicle owner and they wear the chance of f***ing it up on there own head not mine :lolno: Anyways I'll start by saying as far as the CE dash and door cards onto the CC mod goes I would suggest buying a sh**ter CE to raid for parts because you'll use alot bits and peices from both. onto the doors.
What I used:
Tools to strip and assemble doors
A pair of donor CE doors complete ( I used doors off a CE Mirage because thats what I have in the shed)
Angle grinder with bucket brush, flapper disk or both, 1mm cutting wheels.
Drill and 4,6,8mm bits or a step drill. (sharp bits are your friends)
Air hacksaw and something to run it.
MIG welder.
Body filler.
Primmer.
Probably a few other things we'll get to.
You will also need.
confidence in welding panel steel and be willing to make it look worse before it looks better :lol:
After completely stripping both doors down to a bare shell, Door latch dosent need to come out but windows, regulators, rubbers lock rods ect.
Start with the CE door. There is a very distinct curved step on the inside panel of the door shell that runs down from the top rear of the door and along the bottom to the lower front. scribe a line through the lower radius of this step, this becomes you cut line keep it straight and neat this line need to go al the way to the spot welded seem at the front lower of the door.
now move up this seem to the top front of the door and locate then spot welds joining these panels, drill them start with a small pilot it's easier to get it centered. if you get it right you should only have to drill out to 6mm to pop the welds go 8 if you need to.
drill any spot welds around the top corner below the mirror.
using the grinder, cut previously scribed line aound the back and bottom of the door, use an air hacksaw for the curve as the grinder will remove to much material when cutting a curve. carefully remove the entire inside panel clean the edges remove all paint ect about 20mm in from the edge and set it aside This is a pic of the CC dor but the door will look like this
Once you've safly placed the inside panel aside throw the rest of the door over your left shoulder it now an anchor.
Now do the same to the door of you beloved weapon however instead of drilling the spot welds, this time grind them through the first panel leaving the second intact as the inside panel will be thrown away and avoids having uneeded holes in your door making it harder to weld back together. measure 10 times against the replacement panel and cut once, giving youself about a 1mm overlad all the way around.
once you removed it chuck it in the scrap pile. Clean up the edges and remove paint as before.
now lift the new panel on line it up and clamp it into pace.
Tack it into position, remove the clamps.
At this point hang you new door card to ensure everything lines up perfectly, if so weld it down the back and along the bottom respot the front or stitch it if preffered .
you will have a gap in the top front corner I took an angle from the CE door below the mirror which fit nicely stitched it to the door and the inner pannel to support that corner.
Now if needed clean up your welds I etch primed it and used a bit of bog on my thumb just to smooth it off before I primed it.
Smooth it off prime and paint it and walla. Your new CC/CE hybrid door.
Assembly is as normal when you get to the lock rods the one for the door handle needed to be straightened out a bit to gain a little extra length and the locking mech rod needed to be straightened then shortened about 15mm. do do this you really need it in front of you to figure it out. Hopfully this might help a few guys out but as I said make sure your SURE!! before attempting it as there is no going back once you start cutting. This was a suitable method for me,
Door card fitted.
What I used:
Tools to strip and assemble doors
A pair of donor CE doors complete ( I used doors off a CE Mirage because thats what I have in the shed)
Angle grinder with bucket brush, flapper disk or both, 1mm cutting wheels.
Drill and 4,6,8mm bits or a step drill. (sharp bits are your friends)
Air hacksaw and something to run it.
MIG welder.
Body filler.
Primmer.
Probably a few other things we'll get to.
You will also need.
confidence in welding panel steel and be willing to make it look worse before it looks better :lol:
After completely stripping both doors down to a bare shell, Door latch dosent need to come out but windows, regulators, rubbers lock rods ect.
Start with the CE door. There is a very distinct curved step on the inside panel of the door shell that runs down from the top rear of the door and along the bottom to the lower front. scribe a line through the lower radius of this step, this becomes you cut line keep it straight and neat this line need to go al the way to the spot welded seem at the front lower of the door.
now move up this seem to the top front of the door and locate then spot welds joining these panels, drill them start with a small pilot it's easier to get it centered. if you get it right you should only have to drill out to 6mm to pop the welds go 8 if you need to.
drill any spot welds around the top corner below the mirror.
using the grinder, cut previously scribed line aound the back and bottom of the door, use an air hacksaw for the curve as the grinder will remove to much material when cutting a curve. carefully remove the entire inside panel clean the edges remove all paint ect about 20mm in from the edge and set it aside This is a pic of the CC dor but the door will look like this
Once you've safly placed the inside panel aside throw the rest of the door over your left shoulder it now an anchor.
Now do the same to the door of you beloved weapon however instead of drilling the spot welds, this time grind them through the first panel leaving the second intact as the inside panel will be thrown away and avoids having uneeded holes in your door making it harder to weld back together. measure 10 times against the replacement panel and cut once, giving youself about a 1mm overlad all the way around.
once you removed it chuck it in the scrap pile. Clean up the edges and remove paint as before.
now lift the new panel on line it up and clamp it into pace.
Tack it into position, remove the clamps.
At this point hang you new door card to ensure everything lines up perfectly, if so weld it down the back and along the bottom respot the front or stitch it if preffered .
you will have a gap in the top front corner I took an angle from the CE door below the mirror which fit nicely stitched it to the door and the inner pannel to support that corner.
Now if needed clean up your welds I etch primed it and used a bit of bog on my thumb just to smooth it off before I primed it.
Smooth it off prime and paint it and walla. Your new CC/CE hybrid door.
Assembly is as normal when you get to the lock rods the one for the door handle needed to be straightened out a bit to gain a little extra length and the locking mech rod needed to be straightened then shortened about 15mm. do do this you really need it in front of you to figure it out. Hopfully this might help a few guys out but as I said make sure your SURE!! before attempting it as there is no going back once you start cutting. This was a suitable method for me,
Door card fitted.
