Land Rover door repairs

[excossack]

I have been doing some door repairs on the Landy 110. Amazing the amount of rust / corrosion.
Let the pics speak for themselves!

Rear drivers passenger door
Started like this after some poking



After a bit of cutting


Inner part of the frame fitted


Repair section cut to fit


The door has since been painted, but I have notice a weld didnt take so I need to flap disc down, re-weld and re-paint

 

[Robotstar5]

The back door on my 90 was worse than that just by chance when I went to collect a replacement back axle to do a drum to disc conversion they had some doors in and I found a decent rust-free one for £50 even the same colour as mine!.

 

[excossack]

That was a bonus. So far I have done both front doors and also the rear passenger door. The last one is the rear door as the frame has cracked either side of the window and I get a selection of rust drop out from behind the door card as well.

 

[The Buddah]

Did you use a peice of box section?

 

[excossack]

Nope. just bent some plate and welded in

 

[Robotstar5]

The last one is the rear door as the frame has cracked either side of the window and I get a selection of rust drop out from behind the door card as well.

That's how mine went, I think the hinge was stopping the top half falling off my door card was that far gone I replaced it with a piece of Al chequer plate.

 

[excossack]

I have hopefully slowed down the rust moths for a wee bit at least. I have three cans of cavity wax left to inject into the doors

 

[graffian]

That's how mine went, I think the hinge was stopping the top half falling off my door card was that far gone I replaced it with a piece of Al chequer plate.

When I got my ltwt in 2000, it had a patch on the door frame full length of the door just below the door top, I slammed the door one day[soon after I got it] and the patch fell off;-)

 

[ronan]

Why won't the welds take ? Are the original landy panels galvanised or something ?

 

[excossack]

I think it was more me than LR. I was using Zinc coated sheet and I dont think I had a good enough earth / cleaned up the metal good enough. The other welds went OK.

 

[lotus_esprit_s1]

If you can afford it, and can find a pair which aren't nicked, the 05 onwards doors are so much better than the old type. They are one piece pressed construction with no water traps and proper drain holes, and galvanised. They shut with a car like clunk not rattle like the old ones. It only took them 22 years to sort out! I have a set on both my 300tdi defenders (along with galvanised chassis and bulkheads!)

 

[Rocketman]

Just out of interest how old are the landy when they start getting corrosion like that?

 

[awemawson]

If you can afford it, and can find a pair which aren't nicked, the 05 onwards doors are so much better than the old type. They are one piece pressed construction with no water traps and proper drain holes, and galvanised. They shut with a car like clunk not rattle like the old ones. It only took them 22 years to sort out! I have a set on both my 300tdi defenders (along with galvanised chassis and bulkheads!)

Are galvanised bulkheads now available then? Always used to only be the chassis that was available on the aftermarket.

 

[excossack]

Mine is a 1999 model

 

[CompoSimmonite]

Just out of interest how old are the landy when they start getting corrosion like that?

Came as standard from the factory. I'm not joking !. I had a brand new genuine 109" chassis and when I stripped the paint off found they'd just painted over surface rust - no wonder Series III's rotted so badly. As far as the door frame are concerned only the visibly outer areas have any sort of protection. The aspects covered by overlapped alloy and internal areas are just bare metal so you can expect rust to appear first time they get wet or in damp atmosphere. I had a rear door, that had come off a warrantee claim for alloy corrosion, which was under 12 months old. I stripped the alloy off ready to attach a new skin and found the frame already covered in surface rust.

Paul H

 

[Rocketman]

So it's nothing to do with a rough life it's the actual lack factory corrosion resistance.

 

[excossack]

Some additional waxing/rust prevention would not have hurt!

 

[lotus_esprit_s1]

The doors were completely rubbish, alloy skins and steel frames caused electrolytic corrosion on the alloy skins. The water would run down from the windows and then get trapped between the skins and frame at the bottom. They had inadequate drain holes that got blocked in no time and the door would then retain water in definatly.

The rear door was sorted first in 2002 with a one piece pressing in galvanised steel with a galvanised steel skin and a proper window seal instead of just relying on putty and alloy strips. The front doors were redesigned in the same way in late 2005.

Regarding the bulkheads I bought a three brand new TD5 ones about 8 years ago when land rover were clearing them out. I had them blasted and hot zinc spray galvanised. They cost £160 from main dealers at the time! One has been on my 90 for 6 years and parked 10m from the sea and not a hint of corrosion anywhere.

 

[Robotstar5]

Regarding the bulkheads I bought a three brand new TD5 ones about 8 years ago when land rover were clearing them out. I had them blasted and hot zinc spray galvanised. They cost £160 from main dealers at the time! One has been on my 90 for 6 years and parked 10m from the sea and not a hint of corrosion anywhere.

They were wax injecting the bulkheads from mid 90's onwards to cut down corrosion.