Removing side intrusion bar

[ONE600]

Any one have advice on how to remove this? Its harden steel and it takes like 2min to cut 1mm with an air saw. In case your wondering I have full cage with side intrusion bars so I have no need for this bar.

Thanks

[GIPONU]

sounds about right... unless you use some sort of laser cutting device...
i think you posted the wrong picture btw

[ONE600]

ITs the correct picture, its the wide plate in the door that I would like to remove

[GIPONU]

dude thats barely a bar.
umm one method i see people use is a die grinder, but with a cutting disc on the end. should work most efficiently

[ONE600]

It doesnt look like much but its seriously heavy. Angle grinder is always an option but there's a high chance I might go right through the skin of the door as its so close! thanks anyways

[hondapop]

Pretty sure it's also spot glued to the door skin as well to prevent rattles (apart from strength). I can see you're trying to reduce as much weight as possible but is the risk to the skin worth it?

[ONE600]

Well pulled out the angle grinder and here are the results.




It was actually pretty easy with the grinder, just had to be careful not to cut the leavers for the door mechanism.

From full trim to what it is now I have saved easily 11kg per door, well worth the effort

[hondapop]

Congrats! Thought the glue might have been more of a problem but looks like it wasn't holding on by much. Bet the heart was beating a bit faster when you were cutting through the bits close to the skin though.

Now that I've taken another look at the bottom pic I can see that whoever put the glue strips on didn't even get it in the right place!

[GIPONU]

the glue isnt a problem, trade specialists cut that glue like butter.
and with the grinder, you need patience with it.
atleast the job is half done now.hahah

[ONE600]

door is almost complete

[GIPONU]

thats quite cool.

[DNYALL]

awesome work with the doors mate

I am about to attempt a similar thing, although I only have half cage so have to keep the intrusion bars, still gonna cut most of the front skin out though. Was just curious, what windows will you be using? Poly? If so where are you getting them done? I have been trying to find a place in VIC for a while, but no luck yet.