 | Home > 130 > Station wagon conversion troubles... |
 
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| Vesuvius Member Since: 06 Aug 2016 Location: Northumberland Posts: 17  
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I recently purchased this superb defender fresh from rebuild and have inherited one or two troubles with it. I am wondering if anyone can come up with some advice on how to best sort out a panel issue...
First of all here is the vehicle side on...  Click image to enlarge The issue I have is an ill fitting passenger door. Drivers door (this is a RHD vehicle) fits fine. In this picture you can see my problem. The passenger door slams against the load area side panel. The overlap is a couple of mm. The door hinge is adjusted to max. Click image to enlarge I believe the trouble is due to the rear panel being a few mm too long! Here is why I think that... This is the driver door fit... Which is pretty much spot on. Click image to enlarge However... This is the rear panel on the driver side... Look closely; it actually overhangs the rear tub by around 4mm. Click image to enlarge Now look at the passenger side... There is no overhang and a flush fit. Great for the rear but that 4mm is about the size of my passenger door fit issue. Click image to enlarge So the question is... How should I fix this? My options are... 1. Remove both sides, remove structural bits, refold to 4mm shorter, re drill all holes, refit, paint. 2. Somehow encourage the passenger side panel rearward to match the driver side. In doing so I think I get away with just a few holes reamed out to achieve some adjustment. Is there some other possibility I've not considered? |
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8th Aug 2016 4:01pm |
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| apachecow Member Since: 12 Apr 2016 Location: Yorkshire Dales Posts: 59 
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Have you tried a block of wood and a couple of taps with a hammer?
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8th Aug 2016 4:05pm |
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| pj2106 Member Since: 20 Dec 2012 Location: Huntingdon AKA The Shire Posts: 1500 
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Try adjusting the door hinges they do have some movement 2008 110 2.4 XS Utility (Hagrid)
2002 90 TD5 Hardtop (Sully) Sold 1998 300TDi D1 (Billy) Sold |
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8th Aug 2016 4:09pm |
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| Vesuvius Member Since: 06 Aug 2016 Location: Northumberland Posts: 17
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Hammer and block has not been deployed yet!
Door hinges are maxed out. My hope is that I can slot the bolt holes and achieve that precious 3 to 4mm that way but it isn't precision defender owning as I had imagined it! |
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8th Aug 2016 5:15pm |
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| apachecow Member Since: 12 Apr 2016 Location: Yorkshire Dales Posts: 59
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I've seen worse fitting back doors on brand spanking new ones.....
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8th Aug 2016 5:27pm |
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| Vesuvius Member Since: 06 Aug 2016 Location: Northumberland Posts: 17
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Thanks all.
Will report back after trying the block of wood. |
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8th Aug 2016 5:47pm |
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| davew Member Since: 02 Jan 2012 Location: North Yorkshire Posts: 888  
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There's quite a lot of adjustment available in the standard bolts. Defender body panels have never been particularly accurately built so they are built with that in mind. You'll probably find that if you loosen off all the bolts on the side panel, top and bottom, you'll be able to move it far enough backwards.
There is also some scope in tilting the bulkhead forward and lifting the front of the back body but only go down that route if you have a LOT of patience and a bad case of OCD. Lining up Defender bodywork is all about finding the best compromises between the panels. http://www.yorkshireoffroadclub.net/ |
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8th Aug 2016 5:58pm |
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| GREENI Member Since: 22 Aug 2010 Location: staffs Posts: 10379
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As Dave said, it's doable, but it will be a case of a lot of loosening bolts and lots of help with friends, as you move stuff to fit, get somebody tightening things.
There's 2 brackets that come off the bulkhead and go forwards and mount on to the chassis, these have lots of adjustment with 'long holes' ( the technical word I don't know  ) and you can move things around.
It's all a bit tricky! I'd move the side panel back inline with the tub, and work from the bulkhead, then there's a surprising amount of movement in the 4 holes of each hinge  |
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8th Aug 2016 6:49pm |
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| Vesuvius Member Since: 06 Aug 2016 Location: Northumberland Posts: 17
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The job is underway.
Loosening bolts wasn't enough. I've removed everything in the hope of seeing a bit more willingness to move... The issue I have now is the gasket between tub and sides (thick foam one) seems to have a pretty strong grip on things. I can't get any lateral movement in the side panel at all. I think I'll strip more bolts to loosen the roof and then that should relieve some pressure. I'm getting mobbed by midges so will continue a little later. __________________________ I've got previous... 2004 DCPU Td5 - GKN overdrive, warn winch, truck man canopy 2005 G4 D3 2012 D4 HSE 2013 D4 HSE |
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8th Aug 2016 7:41pm |
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| Guy Member Since: 11 Feb 2013 Location: St Eval, Cornwall Posts: 250
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I remember seeing that beast for sale. What a beauty! Hope you get it sorted.
DINGO - '99 Discovery 2 V8 with 300Tdi transplant, chawton white. Repatriated from Australia and expedition prepped. **FOR SALE** SHARKY - '06 Discovery 3 HSE Auto, bonatti grey. SOLD. GEORGE - '99 Discovery 1 300Tdi Auto, willow green. Daily driver, travel companion, part of the family! SOLD. PINGU - '96 Defender 110 300Tdi station wagon. SOLD. Dream LR - 130 pop top station wagon camper. |
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8th Aug 2016 10:01pm |
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| mk1collector Member Since: 17 Sep 2009 Location: West Yorkshire Posts: 6769 
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Could you not take it back to where you bought it for them to fix? Ray
My build thread http://www.defender2.net/forum/topic17615.html |
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8th Aug 2016 11:59pm |
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| Vesuvius Member Since: 06 Aug 2016 Location: Northumberland Posts: 17
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Private sale. I knew about the commissioning issues!
It's definitely just misaligned - needs more encouragement than I can give it on my own so I'll try again when I have some help on hand. __________________________ I've got previous... 2004 DCPU Td5 - GKN overdrive, warn winch, truck man canopy 2005 G4 D3 2012 D4 HSE 2013 D4 HSE |
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9th Aug 2016 7:16am |
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| Vesuvius Member Since: 06 Aug 2016 Location: Northumberland Posts: 17
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So the side panel has been moved aft. I now have reasonable clearance.
The door, however is not square with the panel. The only explanation I have heard is that the bulkhead may be misaligned. The somewhat avant garde rakish angle of my bulkhead does at least mean I probably have the most aerodynamic 130! __________________________ I've got previous... 2004 DCPU Td5 - GKN overdrive, warn winch, truck man canopy 2005 G4 D3 2012 D4 HSE 2013 D4 HSE |
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9th Aug 2016 9:10pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 326
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Same issue for me in my 110. I undid the roof, sides and used some ratchet straps/persuasion to improve things. I do however think that the bulkhead is no fitted properly so if I ever rebuild I will be able to satisfy my OCD but I am happy to live with it for now.
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9th Oct 2016 9:22am |
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