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For simplicity of fabrication door panels will likely be plywood with foam and fabric or vinyl skin. Make door pull out of solid wood (easy to sculpt). Probably cover fasteners with cosmetic plastic caps or paint faces to match door trim. Find cosmetic aftermarket door handle and window crank.

That sounds ultra rugged. I guess you will be putting in much larger door hinges too. :)

I'm doing the same thing. The project of fabrication won't start in earnest for a bit so I'm looking to have spare parts around to at least get everything the same fastener and washer. I'll probably bet getting into the dash soon enough to fix some bad wiring and add outlets and such. :) If you...

that sounds perfect. Any idea what length?

The Mechanical Engineer at work was nice enough to help. The fastener is a M4 which makes it easy to search.

ok I took another look. I can get Zinc and Stainless versions. Also looked. You can epoxy paint stainless but you need to abrade them first. I do have a small paint booth in my garage and a sand blaster so I could make a batch to match the interior color.

We have a local fastener company called Olander which has amazing selection. I have paired it down to machine screws with a washer built in. I will probably go with torx because I think it fits this application and I have torx drivers. Now I just need the length...

It looks like my truck was reassembled with random fasteners in the dash and doors. Has anyone found a good bolt with a captive washer or a large head? Sent from my SAMSUNG-SM-G930A using Tapatalk