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Old 03-07-2021, 12:33 PM   #1
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Removable aluminum door panel design

Hi all,

Iíve 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.
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Old 03-07-2021, 12:41 PM   #2
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Nice, looks great.
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Old 03-07-2021, 01:50 PM   #3
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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.


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Old 03-07-2021, 02:14 PM   #4
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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
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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 donít.

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 ďaccessoriesĒ I want to try making and having one or both of those options would be great.
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Old 04-23-2021, 03:54 PM   #6
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Iím not sure anyone is following my project but I redesigned the ďwing nutsĒ for the removable panel and printed them in Red PET-G filament. My girlfriend says they look like tiny firemen hats.
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Old 04-23-2021, 04:09 PM   #7
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I follow all cool projects, whether or not I have a need for it. Looking really good.

FWIW, I think they look like the tops of of a fire hydrant.

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Old 04-23-2021, 04:22 PM   #8
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Thank you Herb I really appreciate it! They do look a lot like the top of a fire hydrant.

I wanted to design/print my own wing nut that was smaller, and had a shape that was hopefully less likely to cause backpacks, bags ect hanging from the aluminum panel to accidentally snag on the wing nut.
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Old 04-23-2021, 04:29 PM   #9
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Agree, look real good. Reasoning makes total sense too.
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Old 04-25-2021, 11:14 AM   #10
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Thank you Marret!

I finished the panel as well as the 3D printed spacers and wing nuts so I put it all together. It only takes about 15-20 minutes to install. Six bolts are placed in existing factory holes in the door so NO drilling required! Once the bolts are tightened, a spacer is added to each nut/bolt and then the panel is mounted. The panel is held in place with a wing nut that can be tightened by hand for mounting the panel or loosened by hand to remove to panel to be able to easily add any variety of molle style bags/packs or other items. The panel is made from 0.125 aluminum and all of the bolts, washers and nuts are stainless. The 3D printed spacers and wing nuts are printed from PETG filament. Below are a few step by step pictures.
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