Doors & Windshield for Rocky

[Bob R1]

You may have noticed that I revived a couple Threads from 2019/2020 of Rifleman 1981 about his Windshield and Door and Cab and Cable Operated Twin Stick project. I believe that he changed directions along the way when he came up with a CJ Scrambler Cab. He did not do a single build thread. I ended up looking as several threads to get a handle on his build. I never did locate a Finished Project Picture with new paint. From what I could gather he used:
CJ7 or a TJ Door Frame
YJ or CJ7 Full Doors
Scrambler Cab
Cable Operated Twin Stick Shifter from an old Jeep. No idea who sold this conversion for a Jeep.

I am seriously considering using a donor YJ to do doors and a better windshield on Rocky. I currently have a Fortress Roof with the Tilt Out Windshield with a Single Windshield Wiper on the drivers side. From what I can tell the YJ Windshield is pretty much a direct bolt on after doing some cutting on the Roll Bars. Unsure about how much will be required to install the doors. This may require some custom fitting. However the doors should be worth the effort from what I can tell.

DONOR YJ
I just got home with the Donor YJ. Bad Motor?, Rusted out Frame, and Rusted out Floor. I plan to air up the tires before unloading it off the trailer. The last Inspection sticker on the windshield looks to have been 2013. It has been parked for a while rusting. The cloth top rotted down and then the floors rusted out. This one has Jeep Factory Half Doors, and also comes with the Upper Wire Frames. The Windshield Frame looks good, but the Windshield is cracked. The Windshield Gasket does not look real special either. This will be a good excuse to clean up the Windshield Frame with the Glass out of it. This should be an easier conversion than Rifleman 1981's project. Fitting the Scrambler Cab I am sure was a head ache.

WHAT I HOPE TO ACCOMPLISH
Better Windshield with vastly improved Windshield Wipers on both sides, and synchronized to work together. Factory Jeep Windshield Wipers should be a very good improvement.
Half Doors that have a top section. The top section can have new factory canvas with plastic windows with a call to BestTop. Easy fix back to brand new condition. I really like the idea of half doors on the Roxor, however none being made with a top half leaves a lot of room for improvement. I am hoping this is as good as Half Doors get on the Roxor.
The Factory Half Doors have a good Latch Assembly that can be operated from both sides. Huge improvement over most Roxor Doors.
My hope is to take the front Roxor Roll Bar most of the way to the windshield then have it drop down for connection to the YJ Windshield like factory using the Front YJ Roll Bar section with the bolt on flange. This will take care of the Windshield being short, causing the Roof to be Too Low for comfort.
A new Roof will need to be fabricated that seals up much better than normal on a Roxor.
Another improvement will be the YJ Sun Visors. Much better than my Roll Bar mounted ATV Sun Visors.
Also hoping to get working Windshield Washers while I am salvaging parts.
I will need to figure out the Windshield Wiper Switch. Hoping a simple two position Rocker Switch will work out.

This project may take till next Summer to complete, if I keep shopping my daily drivers for repairs. I have had my old Farm Truck in the shop twice this month. I will try and start taking parts off the YJ in the near future, and cleaning them up. Deer Season is two weeks away. I will probably hold off on taking the Roxor Apart until Deer Season is over.

Bob R

 

[Bob R1]

Thursday 10/30/2025 The Rain has stopped for a few days. I have things to do today, however I plan to unload the YJ, and start soaking down screws with Kroil Oil. It will be a lot less trouble in the long run not to twist screws off. It would be nice to get the Half Doors off the body for a start.

I did a little looking, and Rear Fender Side Panels are reasonable. Using them might help out with the door installation.

I need a picture of the VIN to determine the year model. It has Square Headlights, so it is a YJ. When I get the windshield off the VIN will be much easier to read.
UPDATE: The 10th Character of the VIN is a J so that would likely mean a 1988 YJ per my search.
That would mean an AMC 258 Six Cylinder, Peugeot BA10 5 Speed Transmission, and a NP207 Transfer Case. Front Axle will be a D30, and the Rear Axle will be a D35. Most likely 3.07 Gears.

UPDATE: I got the tires aired back up, and I now have the YJ Unloaded off the car hauler. I doused it down with Kroil Oil. Hopefully I have enough on it to do some good getting the Doors and Windshield off.

Bob R

 

[Bob R1]

My brother came over after work today. We positioned the YJ next to the barn/shop so that I will have electrical power available during disassembly.
I managed to get both half doors off fairly easily.

I called Rifleman 1981 this evening. We talked for half an hour or so. He is going to go over what he did on his Scrambler Cab Conversion (2019/2020) tomorrow, and we will talk again. He also did a Twin Stick Cable Shifter. I am sure that it is not available any more, but still interesting.
I am hoping to get the Windshield off this weekend.

Bob R

 

[Bob R1]

Well weekend is here. It is 6AM Saturday morning. Today is my brothers birthday, the big SIX O for him. We will start the day meeting our boss at Betty's Diner for breakfast. My brother is wanting to go by the Amish Meat Packing House and pick up a really good steak for his birthday. We will fire up my 26" Weber this afternoon and cook it to perfection.
In my last post we rolled the YJ into a good spot to start work on it. While waiting on my help to roll it into place, I took a few minutes and cleaned all the junk and trash out of it. I mentioned the 2013 Inspection Sticker. While cleaning it out I came across license plates that were also dated 2013. It was setting for a while. I found a canvas tarp in the Jeep, so someone mush have tried to cover it up at some point over the years.

Today I will try and get the Windshield off of it, and remove the Door Hinges. When I get that far along I will next need to look over the Door Strikes and see exactly how they are mounted in the door opening. Then remove what ever I need to, to reuse them.

I have read that the door opening on the Roxor were larger than a ???, making getting in and out easier. This must have been compared to an old CJ2/CJ3/CJ5. The Roxor Mirrors were in the road doing a really good mock up, however just holding the YJ Half Door up I am pretty sure the new doors are longer than the door opening on the Roxor.

I will need to get the door hinges mounted on the Roxor to get a good handle on how the YJ Doors fit in the door opening. I am really hoping that the somewhat fit front and bottom.

More to come, hopefully today.

Bob R

 

[Vinny]

Please follow up on "The Steak".

 

[Bob R1]

Vinny We ended up getting a couple T Bone's approximately 1.5 Pounds each. They were around $25 each.
The bad part was we did not end up cooking them today as planned. It rained off and on all day. We decided to wait until Sunday Afternoon. That will cost me, as the wife will be home from Horse Camp, and I will end up buying another nice steak and a baked potato for her.

YJ PROJECT
Back to the YJ Project. I mentioned the rain. That slowed things down a lot. I removed both lower door hinges today. I now have access to the back of the Upper Hood/Door Hinge Assembly. "Under the dash". The Roll Bars are unbolted from the top of the windshield frame. I have the Eight Hinge Bolts soaking in PB Blaster. With luck I will get the last 8 Bolts out tomorrow afternoon.

ROXOR WORK
I may go ahead and pull the Fortress Windshield off, and take the front bolts out of the Fortress Roof, and loosen the back bolts. That will let me block up the front of the Fortress Roof without removing my Rear Flood Lights from the back of the roof.

I could then start doing some fitting to see exactly what I will need to do. The plan is to keep as much of the Roxor's Front Roll Bar as possible. I plan to mate the Roxor Roll Bar with the YJ Roll Bar close to the windshield frame. That should preserve head room.

More tomorrow.

Bob R

 

[Bob R1]

SUNDAY 11/02/2025
About all I got done today was getting the YJ Windshield Removed.
I ended up buying a new drill bit, and drilling out the Eight Hinge mounting screws. They were not going to unscrew.
The good news the windshield frame looks good. I am very surprised that it is not rusted, given the overall condition of the rest of the YJ. From reading it was supposed to have some special anti-rust finish on it. Looks like the finish actually worked.
I am considering removing the windshield glass to start with, then cleaning up the frame and hinges before painting them.
Again doing research it looks like the windshield is a Glue In installation. The rubber around the glass is pretty much trim. The existing looks to be a little hard, and probably should be replaced with new when installing the windshield glass.
I probably should get Rocky stripped down so I can check the parts fit, before ordering anything.
I am seriously considering Flange Bolts instead of the recessed head Torque Screws to mount the Hinges.
I am also considering a new Windshield to Cowl Rubber Seal, as well as a new Windshield to Hard Top Seal for the top of the windshield. Put in a little extra effort to water proof the installation.

I went on the Rocker Switch Pros site last night looking at rocker switches. I am considering just wiring the Wipers with Low Speed and Hi Speed with an ON-OFF-ON Rocker Switch. Then using an (ON)-Off momentary contact switch for the Windshield Washer. With real windshield wipers I might as well install a Windshield Washer. Just wondering if I should also order a Light Bar Switch while I am at it.
The alternative to a Rocker Switch would be using a CJ7 Switch. The advantage would be Park and Intermittent could be wired up to work, but it would also be a lot more work to wire up. I have been just turning the wipers off to park them. It is not all that difficult to do.

More Later

Bob R

 

[Ted]

I’ll be interested in seeing the finished product, sounds like it’ll be a big improvement!

 

[jbrenza]

SUNDAY 11/02/2025
About all I got done today was getting the YJ Windshield Removed.
I ended up buying a new drill bit, and drilling out the Eight Hinge mounting screws. They were not going to unscrew.
The good news the windshield frame looks good. I am very surprised that it is not rusted, given the overall condition of the rest of the YJ. From reading it was supposed to have some special anti-rust finish on it. Looks like the finish actually worked.
I am considering removing the windshield glass to start with, then cleaning up the frame and hinges before painting them.
Again doing research it looks like the windshield is a Glue In installation. The rubber around the glass is pretty much trim. The existing looks to be a little hard, and probably should be replaced with new when installing the windshield glass.
I probably should get Rocky stripped down so I can check the parts fit, before ordering anything.
I am seriously considering Flange Bolts instead of the recessed head Torque Screws to mount the Hinges.
I am also considering a new Windshield to Cowl Rubber Seal, as well as a new Windshield to Hard Top Seal for the top of the windshield. Put in a little extra effort to water proof the installation.

I went on the Rocker Switch Pros site last night looking at rocker switches. I am considering just wiring the Wipers with Low Speed and Hi Speed with an ON-OFF-ON Rocker Switch. Then using an (ON)-Off momentary contact switch for the Windshield Washer. With real windshield wipers I might as well install a Windshield Washer. Just wondering if I should also order a Light Bar Switch while I am at it.
The alternative to a Rocker Switch would be using a CJ7 Switch. The advantage would be Park and Intermittent could be wired up to work, but it would also be a lot more work to wire up. I have been just turning the wipers off to park them. It is not all that difficult to do.

More Later

Bob R

Bob, FWIW, I recently completed the installation of the GiStore Willys washer / wiper kit. It's a great solution for the Roxor since it's dual, synchronized wipers, and a discrete installation (i.e., motor and mechanism are hidden like a factory install). I also tucked the washer reservoir in near the radiator fan shroud (below the headlight). I altered the installation to use a single speed dash switch for wiper on/off and integrated switch for the washer. It's backlit for easier use at night. I'm quite pleased with the outcome.

Here's the item I used for the switch: https://www.amazon.com/dp/B0C3B27SVK?tag=roxor-20
edit: Just to clarify, I'm not an Amazon or GiSTORE affiliate. (I'm not sure why Reddit tagged me as an Amazon affiliate.). I'm just providing input on what I found helpful.

I'm looking forward to seeing how your install works out!

 

[Bob R1]

THURSDAY 11/06/2025
I got a few more parts off the YJ today. I unbolted the hood to salvage the Hood Hinges just in case I end up needing a couple more hinges for the doors. I finished removing all of the Soft Upper Door Trim pieces. Front/Top/Back
I started removing the Door Strikes. This would be much easier without the seats in the way. The floors are way to rusty to unbolt the seats. I may use my reciprocating saw and just cut them out.
I will cut off the Horizontal Roll Bars tomorrow, just in case we need them to tie into the YJ Windshield.

Not part of the conversion, but I put a way heavier duty Marine/RV Battery in today. Perfect size, it takes up the entire battery box. I also had to adjust for the new battery being taller.

Then we took Rocky out for a spin on the deer lease. We had a nice ride just before dark. We saw a few deer.

Tomorrow I will need to clean up the shop so I have a place to start cleaning up the Windshield and Doors. I picked up sand paper to start preping the windshield frame for paint.
I would like to start test fitting parts, however deer season starts next Saturday. Disassembly will have to wait until after deer season.

Bob R

 

[Bob R1]

11/07/2025
I got both Door Strikes removed from the YJ today. I also cut both Horizontal Roll Bars off about the back of the seat. Just in case we end up reusing the Windshield attachment points. Both attachment points would need repaired if reused.
That is all the parts I can salvage for the Conversion.
Deer Season starts next Saturday, so I am pretty much done with the Roxor Project until deer season is over.

Bob R

 

[Bob R1]

I have been on the YJ area of the Wrangler Forum. The advice that I got on restoring the Jeep YJ Window Frame, was to remove the windshield glass first thing. This will let me know if the Windshield Frame is in good enough shape to clean up and paint. Apparently the Window Frame can be rusted out around the window glass. Much better to discover this before putting a lot of time into sanding and painting the Windshield Frame, and then discover it is rusted out, and needs replaced with a new one. If not rusted out having the Glass and associated trim and gaskets removed will allow a much better paint job.
NOTE: All is not lost if I do need to replace the Windshield Frame with a new one. I will still have all the Wiper Parts, Hinges, Sun Visors, and other miscellaneous parts needed for the installation of the Windshield Assembly. I would end up with a better finished windshield on the Roxor with a new frame, as I would need to remove the Hinges, which would allow me to have them sand blasted to bare metal while off the window frame. A new Primed Windshield Frame, along with sand blasted windshield hinges would equal a very good paint job.

Next I have been in contact with Max. He is looking for his file on the Windshield Roll Bar Flange's that he used on his YJ Windshield install covered in his build history. His Windshield Roll Barr Flange is Waaaaay heavier duty than the factory YJ one. One of my YJ Flanges is broken, and the other has a visible crack. Factory is not nearly heavy enough construction. Max's Flange is up to doing it's job.

Bob R

 

[Bob R1]

11/13/2015
I ran the windshield frame by the Glass Depot yesterday and had the Glass removed. It looks like the windshield frame is in good enough shape to clean up and paint. I have been looking at rattle can paint a little. We have Krylon Camo OD at the hardware store. It is not a great color match. I used it on my HiLift Jack rebuild. I would like to find a can of Krylon Fusion in Matte Spanish Moss. I read somewhere that it was pretty close to Roxor OD. I ran across a source for a spray can of touch up paint. Mail order and minimum two cans at around $20 each can with Tax, and $20 shipping. It was reported to be a pretty good match in Matte, just expensive. Also Hunters Specialty OD is supposed to be a close match.

So far I have not heard back from Max on the Windshield Roll Bar Flanges. They should make the Roll Bar attachment to the Windshield look a lot more professionally done. Not to mention a lot heavier duty than factory.

I am normally off today, however I need to cover for a Dentist appointment, so I will not be getting much clean up done on the Windshield Frame today.

Bob R

 

[Bob R1]

I managed to clean up the windshield frame quite a bit. I did not locate any rust problem. I am close to clean up and spraying primer and paint. I have a couple rattle cans of Krylon Spanish Moss coming in. I read that it was a close match to OD. Considering cutting Defroster slots in the YJ Windshield Frame like a CJ7. The YJ was the first Jeep to have a plastic dash, and Jeep moved the defroster ducting into the Dash Panel.
My next challenge will be cutting all the beautiful wiring going to the Wiper Motor, Rear Light Bar, Interior Rock Light, and my 12 Volt outlet on the rear bulkhead to power my sprayer and seeded. The wires now go through the cowl where the windshield frame will go.

Bob R

 

[Bob R1]

I went by Harbor Freight today and picked up Two more 6 LED Flood Lights for the back of the roof. I already have one mounted in the Center of the Sloped Rear of the Fortress Roof. Aimed right at the spare tire. I will mount these Two on each outboard edge of the roof. That should really light up the rear of the Roxor. One "Center" to light up the Bed, and the Two Outboards to light up behind the vehicle.
I also put an order in with Quadratec for a YJ Cowel Seal, Hard Top to Windshield Seal, and the Seal & Reveal for the windshield glass. All Fairchild rubber. I also ordered a set of Heavy Duty Wipers. This should get the YJ Windshield installed , when I get it painted.
I had previously ordered a set of Heavy Duty/Weldable Roll Bar Flanges for the Windshield Connection. (Max helped me out with a source for them)
Getting my parts together to install the YJ Windshield. Hopefully it will warm up a lot in the near future. The snow finally started melting off today. Still plenty on the ground though. It takes a while to melt off 10 Inches of snow when it stays Blue Cold.
I need to get a couple more Switch's on order. One for the Front Light Bar, and the Second for the Two Speed YJ Windshield Wipers. I plan to wire them Low High and Off. I am not going to worry about Intermittent or the Park Function. Still considering a Windshield Washer.
Bob R

 

[Bob R1]

PAINTING WINDSHIELD FRAME:
I put Three Coats (One Can) of Krylon Fusion in Spanish Moss on the Interior Side of the YJ Windshield Frame today. It looks great, just not sure about the Spanish Moss color match. I read somewhere that this was the color to use. I may need to make a clean spot on the Roxor to see. I do have Krylon Flat Olive Camo paint that I could use for the finish coats. The Krylon Olive Camo and Krylon Fusion are compatible, per Krylon.

FABRICATION:
Hoping to get my Fabricator Guy on the windshield installation shortly. I will be attaching the Roxor Roll Bars to the YJ Window frame like on a factory YJ. I do not do stupid things in the Roxor , so this set up should be safe enough. I have the new Heavy Duty Flanges for the install. Much heavier duty than the Factory Beer Can Metal used on the factory YJ Roll Bar Flanges, and much better to weld to. Not sure yet what we will do blending the Roof to the YJ Windshield Frame. The height difference between the Roxor Roll Bars and the YJ Windshield Frame is approximately 3 Inches. Planning on keeping the Factory Roxor Roll Bar Height all the way to the front Roll Bar Connection Sleeve, then bending it down to connect to the Windshield frame.

OPTIONS:
Bend a new angle on the Fortress Roof that is on it now.
Make a Filler piece to go between the Windshield Frame and the Fortress Roof.
Build a new Roof from scratch, and sell the Fortress Windshield and Roof Assembly.

NEXT PHASE IN BODY WORK:
The plan is to keep the factory YJ Windshield Angle so that the Factory YJ Half Doors can be fit up as a second phase to the work being performed. The ultimate plan is to have working YJ Half Doors, and close in the sides for year round use of the Roxor.

Bob R

 

[Bob R1]

My Windshield Gaskets and Seals were delivered yesterday evening. (02/09/2026)
I have a couple things to do this morning. I am hoping to start on the Roxor work by noon, or shortly after noon.

GETTING STARTED:
First off will be cutting the wiring and removing the wiring attached to the roof powering the rear 6 LED Flood Light on the Roofs Rear Dovetail.
At that point I will be able to remove the Fortress Roof and Windshield.
Next up will be disconnecting the power to the Auxiliary Fuse Box, and then cutting the wiring harness going through the Cowl.
The next step will be unbolting the Dash, and removing the Windshield Hold Downs for the Fortress Windshield.
I will be lucky if I get all of that done this afternoon.

Bob R

 

[Bob R1]

02/10/2026
Today I got the Fortress Top and Windshield removed.
Cut the Wiring feeding the Wipers, Rear Flood Lights, 12V Receptacle on the BulkHead, and the Interior Light mounted on the Rear Roll Bar.
I also removed the Factory Roll Bars back to the Vertical Roll Bar behind the seats.
I installed the Cowl Seal on the bottom of the YJ Windshield Frame using new screws.
We set the YJ Windshield Frame in Place. The Four Front Bolts lined up pretty well. The Four Side Bolts will require the holes to be enlarged. I bought a new Die Grinder than should do the trick.
I also unbolted the Dash. I have the Right end held up with a couple Zip Ties. With luck my Two Speed Wiper Switch and my Light Bar Switch will show up by the end of the week.

Bob R

 

[Bob R1]

02/11/2026
I went by Glass Plus today. They should have Windshield Glass tomorrow for the YJ. I am dropping the Windshield Frame and Seals off in the morning.

Bob R

 

[Guinnessextreme]

This is a great thread! I dont have a Roxor, but have considered this kind of thing if I end up with one. There have been 7 Jeeps in the family when my kids were still around here and I thought I was over it, but lately it has become apparent that I need one! Will most likely be a Roxor or a JY.

thanks for the taking us along for the ride.