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DIY: How I Assemble A HMMWV / HUMVEE Door / X-Door

Thank you for reading this article.  If you enjoy it, then please comment and share.

This is simply me putting together an X-Door which was recently painted. The goal of this article to simply share what I do.  Said in another way, this isn’t a detailed instructional article which necessarily follows the military process or any other professional process.  Just what I do.

All content here are for reference purposes only: Always consult with an expert if you are not one.

For a detailed list of bolts I used please see here.

With all that said, here we go!

Step 1:  You’ll need bolts, lots of them.

Make life simple for yourself.  What do I mean, when you start to disassemble your first door what you should do is grab a small empty box and gather all of your bolts off of that door.  I don’t try to save all of the washers and nuts.  I try to have one complete bolt, nut, and washer(s) per given set.  Where to me, a set is the number of bolts, nuts and washers you would need to reassemble a given part, or example the the armrest / latch, the hinges, latches …  For example, the latch has 4 bolts, 8 washers, and 4 nuts.  In this case, I would retain 4 of the bolts, two washers, and one nut.  When done you should have all of the bolts, and a single set of nuts and washers per set.  Then, I take this box to my local Fastenal and ask them to gather everything X 4.

Note: I stick to stainless

Note: More than likely Fastenal will not have the exact length for every single bolt.  Whatever you do, don’t get anything shorter, a tad bit longer will be fine.

Note: Consider getting extras of everything.  You will likely lose a few washers and a few nuts.

Step 2: Installing the window.

I like to start off with the door upside-down.  That allows me to slide the window into place by myself.

Note: Don’t forget to install the window rollers.  Otherwise, your window will have too much play within the frame.


When installing the window I like to put the top window rollers in first, then slide in the window frame just passed the halfway point.

Then, I install the bottom window rollers and finally slide the window all the way up and lock it in place.

Step 3:  Installing the window stop assembly

My next step is to install the window stop assembly.  I do this next because I want to make sure the window doesn’t slide off and brake if I accidentally slip the door to the right side up position.

Step 4:  Installing the arm rest / latch assembly

It could be argued if this should be the next step or if should come only once your lock / latch has been installed.  I personally do it next.


Step 5: Installing your Lock

This is very straight forward and not much to be said here.  The only thing to note is that you should make sure not to forget the door spacer that goes between the door and the latch from the inside.


Step 6: Installing the door handle

Next you want to install your handle from the outside.  Not matter if you purchase the locking handles or the standard ones the process should be identical.

Once you have your handle bolted up, not tightened down just bolts, washers, and nuts in place, then you want to connect the door latch road from the actual latch to the actual latch.


Once you have the latch road in place, then you want to make sure your spring is attached and under tension.


Then you want to confirm that your latch will lock in place and released when you unlatch it from the inside or outside.  Test this out a few times.

Step 7:  Hinges

Finally, you want to install your hinges.  You don’t want to tighten down the bolts.  Just get the nuts on and tighten it just so it’s not wobbling.   Once you hang the door and line up the door latch with the striker and only then you want to tighten down the hinges.

Note: don’t forget the spacers behind the hinges

Note: don’t forget to install your limiting strap retaining.  Otherwise, you wont be able to connect the limiting strap from the body to the door and your door will swing open all the way and potentially scratch by rubbing on the mirrors or other doors.

Note: You want to pay attention to the hinges for you do have a right and left.

Here is a time-laps video of everything explained above.

Thank you for reading this article.  If you enjoyed it, then please comment and share.

Check out trucks that Damage Control Customs has to offer here.

Click here for parts offered by Damage Control Customs here.

Click here for a consolidated HMMWV how to articles and videos.

If you have any questions please feel free to reach out directly or fill out the form below and you will be contacted.

Note: Several of the pictures posted on this blog are been pulled directly out of a google search and don’t belong to me.

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New order for HMMWV

The National Guard has put in an order for 739 M1152 HMMWV’s

The dollars keep on flowing,  therefore HMMWV production continues.

Thanks to an article published by shephardmedia I’m happy to announce that we should have just shy of 750 new HMMWV.  The National Guard has put in an order for 739 M1152 HMMWV’s.  This new order is valued at $89 million. This order is in addition to order placed back in Oct 2018.  Delivery of the new order is expected to start Q3 2019. In conclusion,  the HMMWV life line continues.  However, as civilian’s we will likely not see the impact of this for years to come.

What is a M1152 details:

According to AM General, “The M1152 is an Expanded Capacity HMMWV enhanced with Integrated Armor Protection as a Cargo or Troop Carrier. It is a two-man vehicle used primarily to transport personnel, but can also be used as a shelter carrier. The M1152 provides superior troop protection and is capable of carrying up to eight passengers under the Armor Troop Carrier or Troop Seat options.”

If you appreciate the article, then please follow us on facebook, Instagram and YouTube:

If you have questions for the Damage Control Custom’s team, please click here.

To view current HMMWV’s for sale, please click here.

How to download the full spec sheet for the M1152 please click here.

Finally, the full article from shephardmedia please click here.


Have any questions or suggestions?  Submit below.

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HMMWV Cartoon

Check out some of these cool pictures.  I’m having fun turning my HMMWV pictures into cartoon pictures.

I’ve had the pleasure of working on all of these HMMWVs. Turned them from a tough machine to a work of art!





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How do you not return when everyone there loves you.


I have been been at the Caffeine and Octane show several times and I must say it’s one of my favorite events.  They always treat me nice.  Everyone there loves my trucks. And best of all lots and lots of people visiting.


I got to see everything from cute Jeeps, to muscle cars, to fast cars, even cars from Russia.


As you you can imagine I took MasterCraft to the show.


Below you you can check out some of the pictures I took.


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Custom Hood Grills

Special announcement


As promised, this week we would like to disclose our reveal of a special hood grill for the HMMWV.   

But before we do, a quick reminder. By now everyone knows that was the first to introduce special HMMWV hood grills.  I’m sure everyone also knows that we make similar items for 5 ton and can make custom grills with your desired logo.   So, if you would like any of our standard designs for your 5 Ton, or if you would like a custom one made just for you, then please feel free to reach out to us directly. 

With all that said, here is our official reveal of our new custom grill.  We have pre-made only 4 of these for sale but based on demand we will produce more.  You can be one of the very first ones to own it by order here.


We also have other designs ready to ship.  You can order any one of these variations here

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6.5L GEP Turbo HMMWV

So, we’re going to try blogging while on the road.  No, I’m not wring this while driving, I’m atcually at SubWay.  So, I’m headed to the annual IV8888 show.   I’ll be linking up with Jeff from GearReport  and the rest of the IV8888 crew.

Im actually on the road with my newly installed 6.5L GEP turbo motor in my MasterCraft HMMWV.   Just like any turbo she takes time to spool up.  She really shows her true colors at the higher speeds.  Just check out this video of me on the fast lane, kind of going too fast.

She’s doing grea!

While we were at it we also flushed and cleaned the whole cooling system.  It’s so efficient now that I was actually worried about the truck running too cool.

Next note worthy update was an upgrade to a 80MPH Speedometer.


Here are some pictures of the engine.


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AM General up for Sale?

According to it appears that AM General may be up for sale again.   Who wants to create a pool and buy it :)?  Wouldn’t that be nice, but not likely.  Maybe one day, but not today.

According to Reuters: Potential bidders include competitors in the military ground vehicle market, such as General Dynamics (GD.N), Oshkosh Corp (OSK.N) and BAE Systems PLC (BAES.L) according to two people familiar with the matter. Auto makers like FIAT Chrysler (FCHA.MI) and General Motors Co (GM.N) may also be potential buyers, one of the sources added.

What do you think this mean for the private market?  Is this a good thing or a bad thing, leave a comment and voice your opinion.

Let’s keep our eyes and ears close and see how this plays out.



Link to actual article:
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AM General contract to upgrade Army HMMWV

According to the Army has awarded AM General another $51.3 million to modernize the HMMWVs.   This contract was announced by the Department of Defense (DoD) this last Monday.

According to the DoD all work will be performed South Bend, Indiana.  Which is estimated to be completed by end of 2019.

Photo source: Photo by:Maj. Michael Garcia
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How To Install Locking Spindle Nut

This article will focus on installing a Locking Spindle Nut, which can be purchased here.  At the end of this article, there will be a few bonus items.

Note: This article is not intended to replace your Training Manual / Owner Manual, please use this article to only supplement.

For a video of the content below, please watch this YouTube video.

You want to first start with draining the existing gear oil by removing the drain plug using a 5/16 Allen wrench.  The drain plug is items number 4 within the first image below.  You want to open this plug and allow it to completely drain.

Next you want to remove the steering arm cover, which will expose the existing spindle nut.  To do this, you’ll need a 3/4 socket.   Within the first image below, item number 5 is the steering arm cover, and items 6 and 7 are referencing the nuts to be removed in this step.

Note:  You may have to remove the tie rod end / radius rod end from the steering arm cover.  On trucks with CTIS, disconnecting of the arm may be required since it is almost impossible to get the cover back on without folding the lip of the seal.

Next you want to remove all of the old gasket from the steering arm cover and the geared hub.   After which you want to dry off any of the old gear oil.

Next you want to bend back (away from the retaining nut) the locking tabs on your existing lock-washer.  Then, using a retaining nut wrench / socket you want to remove the retaining nut, lock-washer, and keyed washer.

Next you want to start to install your Locking Spindle Nut.  You want to take the notched washer and install that onto your spindle.

Next you want to install your grooved spindle nut per the instructions for your specific vehicle.  In our case, using a 1 3/4 socket, we hand tightened the nut, then using a torque wrench we tightened it to 40 pounds per foot.  After tightening, we spun the spindle 5 times clockwise and 5 times counterclockwise.  Then, we loosened the nut, and tightened it back to 25 pounds per foot.

Next you want to install your locking retainer and and the snap ring.   The locking retainer will have one of 6 position to which it may securely lock onto.   To install the snap rings you will need large snap ring pliers.  It is critical to make sure your locking retainer and snap ring are in place correctly.

Next you want to install your steering arm cover.  To do that, we applied The Right Stuff One Minute Gasket around the steering arm cover.  Then you want to place the steering arm cover in position and hand tighten the 4 bolts previously removed.  Then using your torque wrench, you want to tighten all four bolts to the appropriate torque, in our case 65 pounds per foot.

Next you want to clean off your drain plug and reinstall it.  After which you want to remove your fill plug and replenish your gear oil to the appropriate level.  Once the gear oil has been filled you want to reinstall your fill plug and torque it to the appreciate setting.  In our case, we used 80W-90 gear oil, and torqued the fill plug to 10 pounds per foot.


Bonus content:

Since you have the geared hubs exposed, you might as well as check your bearing.


Since you have the tire off, you might as well as check to make sure your shafts are seated completely.

Since you have the tire off, you might as well as check all of your joints.  In this case we’re going to look at the boll joints. If needed, such as in this case, refill the grease, or maybe consider changing the boll joints.

Thank you for reading and have a wonderful day!