How much weight can be stripped out of a door?

JohnJL · 02-13-2012, 06:30 AM

The car is pure track, with a stout cage built in. I have a little time on my hands and am considering stripping the doors back...how much weight can be pulled out?

Club requirements are for windows that can open and close, so was planning on leaving the glass and motor there, unless there is a plastic alternative that is reasonable to fab and cost.

I guess I'm a bit skeptical just how much weight can come out...the door cards dont weigh much, nor the trim. Speakers are long gone, the pockets and handles are already gone and replaced with a strap.

I dont want to replace the door due to $, was wondering how much people have pulled out...this is a 1983sc.

thanks

Tippy · 02-13-2012, 08:41 AM

Why not remove the regulator and motor?

Just use a strap to hold the window up. Maybe that is not allowed?

aston@ultrasw.c · aston@ultrasw.c's Garage

I just finished a door gutting project: scroll down a bit

Gutted Door Pix?

I saved between 27 and 30 lbs/door, sorry my weights are not more accurate.

aston@ultrasw.c · aston@ultrasw.c's Garage

And here's some info on non-glass windows.

By reviewing various threads and doing some research I conclude the following:

Polycarbonate: (lexan etc) Good impact resistance, poor abrasion resistance and expensive.

Acrylic: (Plexiglass etc) Poor impact, good abrasion but cheap.

So there are now abrasion resistant grades of polycarbonate: Lexan MR10 for example, which is even more expensive. 48" x 48" x 3/16 $300

Or, impact resistant acrylic: Plaskolite Optix for example, a little more expensive but still a bargain in comparison. 48" x 48" x 3/16 $50

JohnJL · 02-13-2012, 11:47 AM

Hmmmm...54-60 lbs would be a nice save...when you say "a strap to hold the window up" can you show a pic of what you mean?

HawgRyder · HawgRyder's Garage

Or...the ultimate weight reduction...a carbon fibre door with lightweight Lexan fixed window.
Bob

NaplesBound · NaplesBound's Garage

I just did what bob said. I love the doors. I went with GT Racing EVO II with a lexan slide window (I know that is against your rules). The doors with window and hinge weigh in at around 9lbs a piece. Original doors are in the 50lbs range.

I feel like 27-30lbs is a bit of a stretch, but I could be wrong.

Take a piece of thin plywood and wrap it in alcantara with a strap for pulling the door closed as mentioned above. Goodluck.

Chris

jhelgesen · 02-13-2012, 04:54 PM

Cut out the safety beams if you want to take significant weight.

jimtweet · jimtweet's Garage

i have a EURO drivers side door for sale, passenger just sold, significantly lighter then US spec door, and can remove safety beam

hpaull · 02-13-2012, 05:04 PM

I have been looking at this too. I was contemplating gutting the doors to get the weight out, but if you can save a bit and are not too strapped for cash remove the doors in good working order and sell them. There is a Porsche dismantler near me and I am just going to be selling them everything I stripped out of my car. I won't get top dollar, but it saves a lot of hassle and opens the budget up for other things.

Once the doors are gutted you can't really go back.

proffighter · proffighter's Garage

Quote:

Originally Posted by JohnJL

Hmmmm...54-60 lbs would be a nice save...when you say "a strap to hold the window up" can you show a pic of what you mean?

Here you can see (drivers door) how the strap works. Fixed at lower end of glass and a modified screw to hang on like a belt (red)

For door lock mechanism I fitted one of an older Peugeot 105 (green), cheap and very light because all plastic.

Removed beam and cut out inner wall. Instead of I glued in a 3mm FG plate.

As I am in the middle of a project, can't tell you weight, it's all disassembled, but I can tell you that the raw door as in the second pic is not heavier than a FG door

JohnJL · 02-14-2012, 03:52 AM

Thanks guys, very helpful.

Does the plexi/lexan/makrolon scratch on the felt or rubber seal on the bottom of the window from raising/lowering?

JohnJL · 02-14-2012, 08:05 PM

And can the safety beams be removed without damaging the outer skin? In situ?

proffighter · proffighter's Garage

Quote:

Originally Posted by JohnJL

And can the safety beams be removed without damaging the outer skin? In situ?

Yes, not much room for working, but I did it. The only thing you have to do is cut the inner wall out first

1100sport · 02-15-2012, 01:58 AM

proffighter, any idea of the beam's weight? Thanks

Quote:

Originally Posted by proffighter

Yes, not much room for working, but I did it. The only thing you have to do is cut the inner wall out first

proffighter · proffighter's Garage

I can't remember exactly, but think it was around 4-5kg each. I can weight the door stripped as on pic on my post, so you can see how much you can save

JohnJL · 02-19-2012, 09:00 PM

The answer was 45 lbs.

Mine is a RoW car and didnt have any beams in there.

Cut them right back and painted in rubberized rocker paint.

jury · 02-19-2012, 11:22 PM

Roll bar extension across the door is work in progress

Chris

aston@ultrasw.c · aston@ultrasw.c's Garage

Quote:

Originally Posted by JohnJL

Does the plexi/lexan/makrolon scratch on the felt or rubber seal on the bottom of the window from raising/lowering?

ANother pelican wrote that lexan scratches just by looking through it!

I used an impact resistant acrylic, Plaskolite Optix and it slides smoothly without scratching. I am using both felt (new) and rubber (old) seals.

RWebb · RWebb's Garage

what does that 45 lb. number refer to?