Door corner fillers for Postal tops

Several people have asked about using standard "round corner" CJ doors with Alaskan Postal and World Cab hardtops which require very hard to find "square corner" doors.

Here's a few photos of the corner fillers I've fabricated so I can use my stock round corner doors with my Postal top.

There's still a little finish work to do, but they provide a good seal and don't look too bad. They're also just in rough paint right now, I'll have them finished the same as the rest of the Jeep before I call them done.

They are made of a 1/2" piece of angle iron bent to follow the countour of the round top of the door, and 20-ga. sheet metal with two 90 degree-bent lips to match the "square" angle of the hardtop opening. These are welded together.

I'm looking forward to finally being able to take this thing through a car wash :-)

Looks like you did a pretty good job to me..way to go.

Truck

Yours look great.

i saw an add on the pirate 4x4 site for a tug being parted out. the cj 10 a has the doors you are looking for.

the guy's email is: rklinger@cox.net

I cannot verify condition or price. i wanted the grille and fenders, but they had been cut up for a custom winch.

Yours look pdg (pretty da#@ good) anyways.

good luck

rick

I just want a postal top.... The doors would be the least of my worries

Looks great, like everything else on that ride of yours

Well done.

jjonesee said:

I just want a postal top.... The doors would be the least of my worries

Click to expand...

Ditto!!!!

It does look very nice.

I think that filler piece looks very good. Can you make a similar piece to fill the outside gap? Then it would look like a factory fit. The outer piece would just be for looks, but it also might keep water from running down the flat inner piece and into the cab. Just a thought. Still looks good like you have it. I doubt any non-jeeper would ever even notice.

Later,

tom82cj8 said:

I think that filler piece looks very good. Can you make a similar piece to fill the outside gap? Then it would look like a factory fit. The outer piece would just be for looks, but it also might keep water from running down the flat inner piece and into the cab. Just a thought. Still looks good like you have it. I doubt any non-jeeper would ever even notice.

Later,

Click to expand...

Yes, I'm considering making an "outer" filler that will go on top of the filler I've currently got in place. This would raise the level of the filler to the level of the side panel. Probably make it out of a piece of solid surface material (Corian, etc.) because it's thick enough, easy to work with bandsaw and router, and can be painted.

Nice job J, the top looks real sweet with the matching paint and the fab work you have had done. I have top envy now!

Thanks for all the nice comments.

One other thought for anyone else doing a Postal top - having done the door corners, I think this is a much better way to go than finding/restoring square corner doors - this way I can use stock replacement weatherstripping, and if a window ever breaks, it won't be hard to find a replacement. Just try finding replacement parts for a square door...

Yeah, but being square is KEWL!

Don't forget that you also can use soft doors and what not too once you have these things...

It's a very ancient thread, but someone asked me today for details of the door corner fillers. I did this drawing shortly after I finished the project years ago, and it was available until last year on my Scrambler site, which is no longer, so here's the drawing.