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34064

Member Since: 12 Dec 2023
Location: South Central
Posts: 202

Front door repairs help and advice required

Good Evening fellow Defender nuts I purchased two second hand non stolen doors off a 2001 90 to go on my 2003 110 as they have minimal corrosion on the frames still need a new section welded in but better than what's left of my current doors. There are also some cracks in the aluminium skin.

Now my question is is there a kit of parts I see SP panels do them but wonder if there are any recommendations for a kit to build a door up without robbing the bits of the current doors so I can leave them on while I'm doing it?

Secondly what is the better door skins to go to is It worth replacing the skin with another ally one or is it better going for a zintec steel skin?

Any help and advice on door rebuild/repair/set up greatly appreciated

Many thanks in advance Tom 110 Td5 Ex Utilities slowly converting into a pop top camper one day

Build thread:https://www.defender2.net/forum/post1024784.html#1024784

23rd Nov 2024 11:01pm

julian

Member Since: 17 Feb 2017
Location: Devon
Posts: 131

1994 Defender 110 300 Tdi CSW Alpine White

I'm currently doing mine.

I wanted to fit central locking actuators, so changed the subframe thing (the bit that holds the window regulator) even though I later found out that it's possible to fit the actuators to the old plate (*)

...anyway, new subframe needs the mounting points moving about on the older door frames. So be careful of that.

Then it's the lock and all the linkages (really, take these from your old door, as they all add up), the window regulator (new ones don't attach to the glass the same as old ones, so, again, care over the parts ordered) and the "felt" kit (just buy a set from sp, as all the bits of plastic will fall apart if you try and swap them over), and, finally the check strap parts.

But, really, unless you just want to hemorrhage money, take the bits from your old doors.

...and get the frames hot dipped before putting the skin etc back on.

23rd Nov 2024 11:34pm

34064

Member Since: 12 Dec 2023
Location: South Central
Posts: 202

Thanks Julian the fact they have been sat in my shed for 18 months I guess tells a story 😅 I guess I just need to get on with it all now I'm just reluctant to take to much of my doors until I'm ready to swap them over 110 Td5 Ex Utilities slowly converting into a pop top camper one day

Build thread:https://www.defender2.net/forum/post1024784.html#1024784

24th Nov 2024 6:59pm

julian

Member Since: 17 Feb 2017
Location: Devon
Posts: 131

You've got work to do before you even need to consider it -

Sort out the welding on the replacements.
Take the skin off (I'd do it in this order, as you may find that the skin helps locating the welded parts)
Blast and galvanize them.
Refit skin or new skin.

...then start thinking about the internals.

(Ie a fair way down the line)

But...

Make sure whatever subframes you are fitting match the mountings on the doors. As I say, the later (puma and maybe late td5, I don't know) subframes do not mate up with the captive nuts on the earlier frames. You need to chop one off and move it, and weld another nut into the frame - it's all easy enough (if you want to do it) but you would want to do it before galvanizing.

If you get stuck I can take some photos. I've got a frame here that has had all the work done and I just need to get it dipped now, so it's all visible enough.

24th Nov 2024 7:06pm

34064

Member Since: 12 Dec 2023
Location: South Central
Posts: 202

I think I'm going to re skin the doors anyway as the aluminium factory skins have both cracked and it will also be easier for paint. I just need to get cracking with it. How did you find the galvanized aftermath did the door frames warp? I had thought about getting them e coated if possible 110 Td5 Ex Utilities slowly converting into a pop top camper one day

Build thread:https://www.defender2.net/forum/post1024784.html#1024784

24th Nov 2024 8:03pm

julian

Member Since: 17 Feb 2017
Location: Devon
Posts: 131

Quote:
How did you find the galvanized aftermath did the door frames warp?

Ill let you know in a couple of weeks!

They're box, so they shouldn't warp too badly, but there will probably be some movement. Thats acceptable to me, as ill bend them back.

I got my bulkhead done, and bits of that flexed, but it was, basically, fine, despite all the horror stories people come out with.

24th Nov 2024 8:06pm

34064

Member Since: 12 Dec 2023
Location: South Central
Posts: 202

Just curious I think I will need to find someone locally to do it atleast it stops me from doing it all again in years down the line. 110 Td5 Ex Utilities slowly converting into a pop top camper one day

Build thread:https://www.defender2.net/forum/post1024784.html#1024784

24th Nov 2024 8:16pm

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