Hello!
This is my first post and I'm happy to be here. I wanted to open a dialog about making doors out of carbon fiber. I understand the process of making a hood, whereas two pieces are molded separately and joined together to make the whole part. I want to start a discussion about making a fully functional door that can accept the oem window hardware and door panel. My concerns aren't necessarily about mounting the hardware, although input is welcomed, as much as the strength of the part when the outer and inner parts of the door are joined together. Has anyone here made a door? Can you please advise me on any techniques or concerns necessary to make a solid door? Obviously the hinges mound to the inner section of the door and the outer door skin would be attached to the inner section. Would the same adhesive used to join the two parts of a hood be used and would they be strong enough? Would it be wise to use a different or additional process to bond these two sections that would add additional strength and functionality? I look forward to hearing from you. Thank you.

It's really exactly the same as making a bonnet. The main consideration is that if you are utilizing a OEM style hinge, then you have the weight of the door hanging off that hinge and you need to make the door skin strong enough in that area to not flex while the doors are open.

Everything else is much the same as a bonnet. Same adhesives are fine, no need to take extra precautions here. The other consideration is crash structure, but this depends on the application. For a race car, you don't need a crash structure other than what is stipulated by your category rules. For a street car, you will definitely want an intrusion bar, and you will want this engineered to meet road regulations.