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Conan



Member Since: 05 Sep 2016
Location: the danger zone
Posts: 53
Belgium 1996 Defender 90 300 Tdi HT Coniston Green
Door repair
Hello all,

I am in the process of rebuilding my safari door. I noticed some rust earlier and thought that if I wanted to do a good job, I should take it appart, fix, treat and refinish it. I have never done this before, so I'm a little confused regarding the order of things I have to do.

So far I have removed the door skin, removed all traces of silicon and anything sticky, and sanded part of the frame. I would like to sand it to the bare metal. I will then cut where the metal is too rusted and weld a new sheet of metal in place.

Then my plan is to:
1. apply rust converter outside the frame and spray some on the inside
2. spray some cavity spray (like you would do on a chassis)
3. apply rust proof paint on the outside of the frame
4. apply some primer
5. put the skin back on the door
6. paint the whole thing

Do all these step make sense? Did I miss something? Or are some steps mixed (not sure when I have to apply the primer)?

One last question: I have a small hole in the aluminium of a part of the door skin. Is there any filler that I can apply, and sand down to get a smooth finish?

Thanks in advance for your guys' help and tips!

Some picture of the work done so far:
BEFORE

Click image to enlarge


Click image to enlarge

AFTER SOME CLEANING AND SANDING


Click image to enlarge


Click image to enlarge

THAT HOLE IN THE SKIN I'D LIKE TO FILL


Click image to enlarge
Post #596796 27th Jan 2017 5:38pm
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Lotus_esprit_s1



Member Since: 01 Oct 2014
Location: Uk
Posts: 201
Buy a new skin from sp4x4
Post #596954 28th Jan 2017 1:47pm
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Balvaig



Member Since: 19 Feb 2016
Location: Fife
Posts: 730
Scotland 2016 Defender 90 Puma 2.2 Landmark LE Corris Grey
Big job you have set for yourself. I am no expert but this is how i would proceed.

For the frame the logical order is:
Rub down
rust converter
prime
paint
For the skin (if aluminium)
rub down
bond an aluminium patch on to rear of hole
fill hole with two part epoxy filler
rub down
apply fine surface filler to smooth
rub down
etch prime bare aluminium
prime
Re apply skin, using sealant to separate steel from aluminium

Repaint

Finally apply cavity spray to inside of door

What products you use is a matter of debate, but try Frost restoration www.frost.co.uk
They have a good choice of products.
Hope this is of some help
Post #596964 28th Jan 2017 2:30pm
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Conan



Member Since: 05 Sep 2016
Location: the danger zone
Posts: 53
Belgium 1996 Defender 90 300 Tdi HT Coniston Green
Lotus_esprit_s1 wrote:
Buy a new skin from sp4x4


I only have one piece of the top skin that is damaged, I wanted to avoid replacing all of them if I could repair mine...
But thanks anyway

Balvaig wrote:
Big job you have set for yourself. I am no expert but this is how i would proceed.

For the frame the logical order is:
Rub down
rust converter
prime
paint
For the skin (if aluminium)
rub down
bond an aluminium patch on to rear of hole
fill hole with two part epoxy filler
rub down
apply fine surface filler to smooth
rub down
etch prime bare aluminium
prime
Re apply skin, using sealant to separate steel from aluminium

Repaint

Finally apply cavity spray to inside of door

What products you use is a matter of debate, but try Frost restoration www.frost.co.uk
They have a good choice of products.
Hope this is of some help


Thanks for sharing your opinion, I am always very optimistic and I thought that it wasn't going to be that big of a job. I think all it's all the prepping and the waiting time between each step that is the biggest pain...

I will try to follow this and I'll take pictures as I am going through the repair, it could be of some help for someone else later on...

Thx again!
Post #597572 30th Jan 2017 9:21am
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Balvaig



Member Since: 19 Feb 2016
Location: Fife
Posts: 730
Scotland 2016 Defender 90 Puma 2.2 Landmark LE Corris Grey
Its part of the fun.
I can understand you wishing to restore not replace.
Just take your time.
I am certain members of the forum will advise on specific products to use if you get stuck.
Post #597579 30th Jan 2017 9:47am
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