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post #1 of (permalink) Old 10-17-2002, 06:41 AM Thread Starter
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YJ full door window frame

Hey guys, I'm somewhat new to this board, and have tried the search, but can't find what I am looking for, maybe you can help.

I have a '92 YJ with the full steel doors. The problem I have is where the window frame enters the door at the rear. I have heard people say that this area is prone to rust, but my Jeep has no rust there. The problem lies in the actual design of the door. The skin on the inside of the door is supposed to "wrap" around the frame and then lap onto the outside skin of the door. The weld where the skins lap onto each other is breaking, due to repetitive closing of the door with the hard top on. I have thought about trying to weld this area back together, but I don't think I could weld it good enough to keep it from happening again. I have also thought about welding around the area where the frame enters between the two skins of the door. Has anyone ever tried to do this? I am somewhat hesitant because I am afraid that after welding, the actual weld will be harder and more brittle and that the constant closing of the door will cause it to crack again anyway. I have thought about getting a new door from a junk yard (read dead Jeep Heaven), but I can't seem to find a decent door in my area that is still in decent shape.
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post #2 of (permalink) Old 10-17-2002, 08:37 AM
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Re: YJ full door window frame

Never actually seen anything on here about it, but I have seen the problem a TON.

I bought a pair of doors second hand and the reson they are still in the garage and not on my Jeep is precisely this problem..

I opted to tear them down and rebuild them as I wasn't 100% sure about any part of them.

I'm sure welding it good would fix it.. but the best option is to open them up, isolate the problem part and fix it properly. Would it be a problem if the door went another 9 years without breaking?
Not for me..
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