Our client encountered difficulty obtaining a replacement door for one of their on-site electric vehicles, a Carryway electric club car, prompting them to seek our assistance in finding a solution.

In response, we proposed manufacturing and powder-coating a custom replacement.

The images below show the process.

The original glass door was removed from the vehicle to be used as a template for the replacement.

Caddy Door
Door & Profile

A blank pattern was then produced to match the existing profile.

The profile was then produced using 3mm Aluminium Checker plate.

Once the blank is complete, we then powder coat the new door in a ripple finish.

The ripple finish is a stunning and durable powder coating finish that complements the door and lasts in even the harshest environments

Coated Door
Door Inner

The replacement door was then built up using the original locks, hinges and handles.

A new polycarbonate window was created and installed using our bespoke framing steelwork.  

Door Outer

A new door and window seal was then applied to keep the elements out.

coated door in ripple finish

Once completed, the door is then installed and adjusted to suit the vehicle door aperture.

Caddy with door fitted
New door installed
Inside View
New door installed
Front view
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