My pilot door design...

Set up so they will open if your upside down. They cannot fold in you since the main cage hoop on the pilot

prevents that.

remove them in seconds.

Made out of conduit, cheap, easy to bend and stiff enoungh when they are welded up.

So far, They have survived 2 ocotillo wells trips and 1 glamis trip, huge jumps and charging whoops. They have

never opened by mistake.

The only problem I kind of have is the brake line brackets sometimes rotate on the cage and the door latch holes don't line up perfectly. Mainly because I put electical tape on the cage to prevent straches, The tape has got all soft from the desert heat. Its really and easy fix just rotate the clamp and get the hole to line back up again. I'm going to ditch the tape and mabye pop rivet the clamp to the cage.

I couldn't get away from the gap in the front of the door because with my headlight set up, the doors hit the

lights when you open them. The lower profile lights you have the better.

Don't bend a thing until you get your hinge set up. I didn't have the whole thing figured out yet and I had

to make 2 more doors, that's why you buy exta conduit. its like 4 bux for 10 feet.

my light bar was designed to act as a stop for the door when they are open. You don't really need a stop and the doors can open all the way and will just sit on the brake line clamps. You can see the hinges flex a bit; I would suggest you limit this with a string or small chain to reduce fatigue on the hinges.

Make the outer door frame and get your hinges set up. Then sit in the pilot an use some string to simulate the height of the side panel your going to make. A little lower than shoulder height is good.

The parts...

Mc master carr:
Stainless quick release spring loaded hinges
Sping loaded quick release pins for door latches

home depot:
2x 10ft half inch electrical conduit. buy some extra, this stuff is cheap
3/16 and 1/8"pop rivets
Rustolem primer, Sunrise Red, clear coat spray paint
8-32 x1" stainless machine screws, washer, locknuts
3/16x1 or 1.5" flatstock steel
nuts to mount stock mirrors, M6 or 8? I forgot

ebay:
atv a-arm brakeline clamps for 1 1/4" tubing with a 1/4 hole for hinge pivot

window nets:
ebay: .5 or 1"Golf or base ball netting
walmart:1" quilt boarder
someone to sew them
ziptie them on to the doors

metal yard:
18 or 20ga Aluminum for side panels

major tools:
pop rivet gun
conduit bender
mig welder
band saw or plasma to cut side panels
optional: tubing notcher

At first glance or the heading I went Umm. After reading through and viewing pics, by the way very nice pilot. I went from ummm to pretty cool. Any time I see the mention of Electrical stuff it catchs my interest. Thanks for sharing and suppling good detail on parts. I will for sure add you parts and pics to my drive for future refrence.

Thanks Adnoh.

I like it,well done!
I've always thought about doing the same setup on my racing Pilots.
But always get sidetracked into doing other mods,then forget........now you've reminded me,thanks.

very very nice work

McMaster Carr part# please

and Ebay item number

thanks Speed

Very slick!

mc master:

13525A75 2 Sets Quick-disconnect Latch Hinge, 300 Series Ss, W/holes, 1-3/4"h Leaf X 2"w Open

90222A112 2 Each Zinc-plated Steel Weld-in Pull Pin, Nonlocking W/t-handle,3/8"pin Dia,1-1/2"barrel L

Ebay

BILLET BRAKE LINE CLAMP 1 1/4" SIZE TUBING (300483866109)
7'x7' BLACK GOLF NET, MARINE GRADE USED FISH NET #1755 (280727063354)

Great product! Keep it up!!

The pics in this thread look better than your other thread. I first thought the "panels" (doors) popped out like in the other pics and didnt sit as flush as they actually do. Pretty cool idea.

So I am guessing you ride Glamis? There are a few of us on the board that frequent there and also Dumont. We will be planning a Pismo guys trip if you might be interested.

yeah in the glamis pics i didn't have the door latched. The doors sit as flush as you can get since its limited by the cage main hoop.

Glamis and ocotillo are my spots since in live in San Diego but i'll go to Gordons and buttercup once in a while. Pismo is just too far of a drive for dunes that aren't that big, i'm just spoiled going to glamis. I hear Dumont is huge, i'd like to go there someday.

I like Glamis, but Dumont is my favorite place to ride. I am in the middle of all 3 places, for me it is 175 miles to Dumont, 190 to Glamis, and 220 to Pismo, so all 3 are within my range. Dumont has bigger hills, but a smaller riding area than Glamis. I like Pismo just because it is the only spot during the summer heat that stays cool enough to enjoy some dunes.