SAD Defender doors

[Landynut]

My Defenders doors are bit worse for ware so I have decided to give them a make over. Anyone with a phobia of rust look away now.Started with rear door first.

First thing to do is strip back frame to clean metal if there is any and then build a new frame. Any comments or advice gratefully received.

 

[weldingscotty803]

ooooooooooooo that looks a bit erm .......rusty lol.
what defender is it off?
you gonna get them galved when finished?
just be careful with measurements etc as defender doors never fit right at the best of times

 

[Arsonista]

First thing to do is strip back frame to clean metal

Do we have a migforum bravery award?

 

[Robotstar5]

Is it worth it?, by the state of the frame, the skin is probably blistering and cracked at the window frame joint - mine wasn't as bad and I bought a decent second hand one.

 

[rtbcomp]

The rear door on my SIII is pretty much the same, I thought of cutting it down and making a swing-aside tailgate for when I drive without the top on.

 

[Landynut]

Its a 1993 Defender 90. Not going to bother getting it galvanized. Have started by removing wheel carrier and have cut out all rusted frame bits. Just going to measure up now and replace with box and flat bar

Some photos










Thats it for tonight will start welding tomorrow

 

[weldingscotty803]

i was also going to suggest buying new or secondhand but i would give repairing a go first.
use a wire brush wheel for the grinder and take it steady
get decent metal and start from there.
keep posting piccies so we can help you out as you go along

atb scott

 

[weldingscotty803]

oooooooooo thats bad lol

 

[stormin]

To all those calling for replacements, the non genuine new ones are even worse than the Land Rover original.

Pattern door framework is only welded on the bits you can see and not on the flats that bear against the skin, so flex is a real problem. There is also no rust proofing between skin and frame.
If you get a replacement you're still going to have to strip it to weld it and strengthen it, paint the unseen parts, then preferably bond the skin to the door frame.

Best replacements are the late model TD5 rear doors which are all steel and a revelation in terms of solidity, fit and finish.

 

[weldingscotty803]

To all those calling for replacements, the non genuine new ones are even worse than the Land Rover original.

Pattern door framework is only welded on the bits you can see and not on the flats that bear against the skin, so flex is a real problem. There is also no rust proofing between skin and frame.
If you get a replacement you're still going to have to strip it to weld it and strengthen it, paint the unseen parts, then preferably bond the skin to the door frame.

Best replacements are the late model TD5 rear doors which are all steel and a revelation in terms of solidity, fit and finish.

cheers for the tip.

 

[Landynut]

Did not get any welding done this evening just have a few bits cut. Will hopefully get welding tomorrow. Here are some photos anyway.

 

[Landynut]

Right storey so far I have got all the bits welded up and painted with primer.Just have to fix door skin on now with panel sealer when the paint dries. Hope this looks like some sort of an improvement from the rusted door I started with. Just two more to do now!

 

[Robotstar5]

Looking good, how are you going to finish the inside, a piece of 2mm 5 bar (chequer) plate? - I'm sure I've seen ready made ones (including lock cover) in one of the Land Rover magazines.

 

[stormin]

Looks a hell of a lot better than before.
I would add some corner braces back in to lend extra stiffness, even if you have no intention of putting the spare wheel back on. All that slamming of the door soon takes it's toll. If the wheel's going to be on there it's essential.