http://www.4wd.com/Jeep-Exterior-Parts- ... =ASM6033KL - This billet door has an OD on the cover of 6-3/4" - Far more than needed to cover an existing KK gas door.
- The door OD is 5-1/8" which would present a near-optimal opening for our KKs. The opening would be larger than our existing door-hole, but smaller than the recess. So, it should look pretty clean, even when opened (which really doesn't matter much, except to us OCD types).
The only downside (and this could be significant) is that it looks like you would have to be willing to drill your body panel to attach the wider OD cover. With a little primer and silicone, one could easily make the whole production weather-tight.
Jeepingirl - Did you just get a replacement door for the KK or put on a whole new cover? (And welcome to LostJeeps!)
I need to get the specs for the official "Jeep" replacement door, as I think it has some of the cleaner lines and might/could be worth drilling one's body:
http://www.4wd.com/Jeep-Exterior-Parts- ... _Container