Ok so I got an 87 T/A, and everyone who owns a third gen camaro/firebird knows the doors are damn heavy haha and in awhile I'll be making my DD into my project, and I was thinking about how to make the doors lighter. They do make fiberglass ones but the windows aren't gonna roll down, so thats a problem. Then, I had this idea, and I want you guys to tell me what you think.
First, I want to drill holes (say, 2") in both the interior and exterior sides of the door, on the inside I'll just put the panel back on and there you go. On the outside, I was thinking of drilling the holes, and then backing them with fiberglass and then filling with resin or body filler, and sanding smooth/blending into the rest of the door. Kinda like you would do when you cut out rust spots and MIG weld circles back in and smooth out with filler. I was just curious, and wanna know what you guys think?? would it work?? I'm guessing you'd save probably 10lbs or so on each door (maybe less... 5lbs?? maybe more??) I have a friend who is pretty damn experienced with body work so I'm sure he could help me out (I'm fairly new but I know my way around)... so yeah, tell me what you guys think.
and yeah, I realize the strength of the door will be compromised.

 

If you drill a hole, back it with fiberglass, then fill with bondo, the end result will weigh more then the original door.

 

Leave it alone.. That door and inner bracing is an integral part in the strength of the car. There would be nothing to help you if you get hit in the door.. Not worth it,

 

Our doors are heavy but there are other places to lose weight that are more effcient then just cutting out holes in your door I would be looking at losing weight at both ends and the top side of the car like fiberglass hood spare tire ect... when I find time I would like to make a mold and make some carbon fiber hoods and trunks

 

especially for a daily driven car you do not want fiberglass doors or doors without inner structures. Getting hit from the side is more likely to kill you if you do. But as mentioned before, fiberglass hood, a lexan rear window, lexan t tops, lighter wheels, etc are better ways to lose some weight.