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Old 03-07-2021, 12:33 PM   #1
Join Date: Nov 2019
Location: Wisconsin
Posts: 60
Removable aluminum door panel design

Hi all,

I’ve been working on designing a door panel for one of the bran doors to be able to mount/strap/bungy a variety of things to all while being able to easily remove the panel from the door without tools if needed to better secure items to it.

I took some measurements of one of the barn doors, to be able to use six existing factory holes in the door and designed a panel on a cad program. I had my design cut out of aluminum. I then designed and 3D printed some spaces to have stainless hex nuts recessed into them and a wing nut style knob that also has a hex next recessed for the tool-less removal of the panel if needed. Also no drilling required for installation!

I still need to do a bit of sanding on the panel before sending it to powder coat and might redesign the 3D printed part of the wing nut.
Attached Thumbnails
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Old 03-07-2021, 12:41 PM   #2
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Join Date: Nov 2016
Location: FL and VA
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Nice, looks great.

2008 GMC 3500 Quigley Weldtec 4x4 Savana SMB
2006 BMW HP2 Enduro-Sold
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Old 03-07-2021, 01:50 PM   #3
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Location: Southern New Mexico
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That looks very functional and very cool.

You may want to throw some sound deadening insulation on the interior cavity wall so it's not a big hollow drum.

SMB-less as of 02/04/2012. Our savings account is richer, but our adventures are poorer.
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Old 03-07-2021, 02:14 PM   #4
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Location: Annapolis, Maryland
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Well done - I really like the bolts coming out from the door... Have you considered making them longer to accommodate a flip down table/door that covers the available storage space inside the door? - that door would sit between the panel and your plate (since the plate could easily be removed for access using knobs that screw onto the protruding bolts on the outside.
I tried something similar with my panel but went another route to hang the panel on the door because my access was limited with the already fabricated door & storage compartment made by SMW - I wanted to keep them in place & remain easily accessible - having both takes advantage of some great storage space inside that door.
Just something to consider.

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Old 03-07-2021, 05:13 PM   #5
Join Date: Nov 2019
Location: Wisconsin
Posts: 60
Thank you Marret!

Hi Herb! Yes! I definitely need to add some sound deadening insulation. A big hallow drum is exactly what I expect it to sound like if I don’t.

Twoxentric, thank you for your reply and sharing your picture! I have thought about doing some sort of flip down table, but an access door or some type would also be a good idea. I have various ideas and “accessories” I want to try making and having one or both of those options would be great.
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