Length: 9:00
Date: March 13. 2025
The SuperATV HDPE half doors are made from 5/8-inch thick high-density polyethylene, offering excellent strength, durability, and impact resistance. These doors are precision-engineered for the Can-Am Defender, offering a tight, secure fit with integrated weather sealing.
In this video, we’ll walk you through the complete installation process—from prepping your machine to aligning and securing the doors. Whether you’re installing for the first time or replacing older doors, this guide covers every step.
Welcome back to Grease the Wheels! I’m Braden Adams, and today we’re in my garage installing these doors on a Can-Am Defender. Before we begin, make sure you’ve gathered all the necessary tools. You’ll need:
Start by unpacking all components from your SuperATV kit. Locate the bulb seal and press it into the groove that runs along the inside perimeter of the door. This seal helps reduce vibration, improve noise control, and prevent dust and water from entering the cab.
Start the seal at the designated point and ensure that the bulb side is facing downward and inward, toward the machine. Press the seal into the channel firmly by hand. The process is simple and only takes a few minutes.
Now let’s prep the filler panel. This panel installs near the door hinges to close off the open gap between the frame and the cab. You’ll apply two types of seals: A strip of adhesive-backed foam seal placed between the notches. And a section of bulb seal that runs from the bottom of the panel upward.
Ensure the panel is facing the right way by checking for the machined-down surface, which should be oriented inward toward the cab. The bulb seal should also face the interior.
To prepare the Defender for door installation, remove the OEM side panel. If your Defender still has the factory bolster, door nut, and latch, these will also need to be removed.
Use a T30 Torx socket to remove the fasteners, and a flathead screwdriver to pop out the push pins from the rear side. While a push pin tool can help, it’s not necessary for just two pins. Once removed, set the side panel and hardware aside.
With the side panel off, remove the factory cage bolts. Then take your long M10 bolt, spacer, and threaded plate. Insert the threaded plate through the interior side of the cage, making sure the threads face outward.
Slide the spacer into the frame and begin installing the lower bracket. The bracket will hook onto the bolt from underneath. Once it’s positioned correctly, rotate it upward and loosely tighten the hardware. This step forms the foundation for the door hinge support.
Take the rear bracket and attach it to the threaded holes on the back of the roll cage. Align it properly, then run the hardware in until it’s snug—but do not fully tighten yet, as adjustments will be needed.
Next, grab the hinge bracket and attach it to the lower mounting bracket you installed in Step 4. Once again, leave the bolts finger-tight to allow positioning of the door later.
Slide the filler panel into place so it aligns with the hinge brackets. Use the short Allen bolts on the exterior and barrel nuts with washers on the interior side to secure the panel.
Make sure you line up the hardware carefully. If the bulb seal on the back is too thick or improperly placed, the filler panel may not seat correctly, affecting the seal. If you followed the initial instructions on bulb seal placement, it should fit perfectly.
The door strap is a crucial safety feature that prevents the door from swinging open too far and hitting the body or another object. Slide the strap into the designated slot and ensure it’s secure. When installed properly, it will stop the door at a controlled point when opened.
Now it’s time to install the actual HDPE door. Align the pre-drilled mounting holes in the door with the hinge bracket. Use the provided Allen bolts and barrel nuts to secure the door. Start all bolts by hand without fully tightening them.
Let the door hang in an open position—this will give you space to work on installing the latch and striker hardware.
Install the striker bracket onto the front section of the roll cage. Use the two long M8 Allen bolts and secure them loosely to allow for final adjustments.
Then insert the striker pin through the bracket using a large washer on the outside, a small washer on the inside, and a nut to hold it in place. Keep this hardware finger-tight for now to allow for alignment with the door latch.
Now it’s time to install the door latch assembly. Attach the latch mechanism to the latch bracket using long M6 boltsand Nylock nuts. Make sure the latch faces forward, toward the front of the machine.
After the latch is secure, install the door handle. Tighten all bolts fully and test the latch movement before continuing.
With the latch and striker in place, close the door and check the gap spacing around the perimeter. If everything lines up properly, begin the final tightening process:
Once everything is torqued down, open and close the door several times to confirm smooth operation.
After confirming proper fitment on the driver’s side, repeat the entire installation process on the passenger side. All steps and hardware are mirrored, so you can follow the same sequence for a symmetrical install.
That’s it! You’ve successfully installed SuperATV’s HDPE half doors on a Can-Am Defender. These doors offer trail-proven durability, improved cab protection, and a custom look that matches the rugged aesthetic of your machine. Order your HDPE doors now via the link in the video description.
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