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Old 12-16-2008, 12:11 PM   #1 (permalink)
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Default Removing doors and windshield?

I'm going to take the doors and windshield off of the '88 Samurai that's hidden in the woods for my wife's Christmas present. We have acreage and she will be able to explore our trails with it, unlike now where my tractor has but one seat and she has to hike.

One of BillJohn's pages explains that the windshield screws have been loctited in and need an impact screwdriver to remove. I've got the driver and when DW is off shopping, I will attack. I have a grinder if that fails. Anything else I should know?

What about the doors? I broke a bit with a ratchet a couple of days ago trying to remove one door hinge screw. I assume the impact driver again?

Is it gonna be ugly under where the hinge attached? Is there a better way? I don't plan on reinstalling the doors ever but would prefer to keep everything undamaged if possible. I could grind off and punch out the hinge pin if the finished job would be better looking.

Any tips are appreciated and I'll have more questions. I'd been planning on buying something like a Kawasaki Mule for her but have you seen how much they want for that or anything like it? WAY OUT of my budget! And there are NO used ones anywhere. Thus she's getting a Samurai and I'm sure she'll love it.

Beats walking.

Phil
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Old 12-16-2008, 02:25 PM   #2 (permalink)
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I pull my doors off all the time with just un-bolting them. Yes they are tight to begin but should come off reasonably well with a proper driver. Worst case scenario use approx 1/4" drill bit and drill until the head of the bolt falls off and then use set of needlenose vice grips to remove the stud portion. I then used a set of bolts that are from a GM product (I can't remember which vehicle) that I bought at the local hardware store in a package. Another option is just drill out the hinge pin itself.

It may be a little ugly under the hinge if the doors have never been off, the factory paint came off with my hinges but it was easy to touch up.

As far as windshield I have allen bolts holding mine together that leads me to believe that it has been removed before and I can't really comment further.

Good luck! Lucky girl getting a gift like this for X-mas!

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Old 12-16-2008, 05:03 PM   #3 (permalink)
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Thanks, PP. That's how it LOOKED but after seeing BillJohn's mention of loctite on the windshield screws I was beginning to wonder if the whole vehicle was put together with the stuff. I'm sure the doors have never been off before but I was unsure whether the body was painted before they were originally installed or after.

Guess I'll try and have some touch-up paint on hand.

Phil
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Old 12-16-2008, 08:05 PM   #4 (permalink)
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You can also cut the hinges with a dremel tool and make it so that you can remove the doors or replace them in about 20 seconds... each. Maybe less. The first time I did a hinge cut on a zook (the one in the picture), it took me about 30 minutes. I also did it without removing the hinges from the vehicle... so no fighting the screws. The doors will only come off as it approaches a 90 degree angle from the vehicle.

Door Hinge

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Old 12-16-2008, 08:05 PM   #5 (permalink)
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for the windshield bolts, just have a little torch and warm it up, will liquefy the lock tite stuff and then you will be able to unscrew them.


on the doors, just cut the top part of the hinge, then you will be able to slide the doors off at anytime, and no problem with paint issues...i will look for a link on how to, be right back.....look at this





that is a little bling, but look at the design, same concept - cutting the top part of the hinge.

best of luck
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Old 12-16-2008, 08:06 PM   #6 (permalink)
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Quote:
Originally Posted by Billjohn View Post
Y
you beat me by like 2 seconds
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Old 12-16-2008, 08:13 PM   #7 (permalink)
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Quote:
Originally Posted by mule View Post
you beat me by like 2 seconds
Tsaright...
I have a set of the 'bling' hinges too. But we have at least two 'how to' articles over at iZook and I just posted the link to the one that I wrote.
Easy to do, best bang-4-the-buck upgrade you can do.
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Old 12-16-2008, 08:17 PM   #8 (permalink)
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[edit] post deleted [edit]

you Bill are better than i, have beat me aat the punch....twice

but yeah you will love riding with the doors off option. heck i leave the top on and have all windows out and doors off
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Last edited by mule; 12-16-2008 at 08:19 PM.
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Old 12-17-2008, 11:28 AM   #9 (permalink)
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Thanks Mule and Bill! I hope to be working on this Saturday, but I'm in the woods with no power so I'll attempt to remove the screws and then modify the hinges and reinstall later. That'll solve the touch-up paint problem at least.

And Bill.... thanks for the link to ZNO and the detailed instructions at your site. I've looked at your pages for over a month and never saw the door hinge instructions. Those billet hinges are nice but I think I'll be doing the mod as you describe.

I don't have a propane torch but do have oxy-acetelene, however I'm hoping the impact driver will be sufficient. Under the hinges looks exactly as I was expecting (this one is white too) so I'll mod and reinstall the hinge halves.

Phil
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Old 12-18-2008, 11:18 AM   #10 (permalink)
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I was able to loosen all the screws using the impact driver. Only one stripped (lower windshield bracket, removing the windshield with the two upper screws and will drill the lower out later).

Now that they're loose, I'll try to take everything off Saturday (only day without rain). Thanks for your help.

Phil
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