Bankz's 110 Double Cab

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Some where a lot worse than others, in order of how fu cked they are
1. Drivers side second row door - Very bad
2. Passenger side second row door - bad
3. Passenger door - New bottom
4. Drivers door - New corners but actually not too bad
 
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Actual pics of the rust

Thankfully the drivers door is in alright condition, the bottom is ok only a few very small holes along the bottom and a couple larger holes on the corners, wont need a new bottom but will need patching.

Ordered a repair section plus new door card fittings from YRM, will be welded up by a pro as it is not something I can do. Hopefully it should be tooo expensive!!

Passenger door front, bottom hinge area
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Passenger door, near side - New bott
om needed
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Started grinding away, same door as above
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That was all bloody filler!
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Top rear doors, where the small rectangular glass is
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Same for the other side
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Not quite as bad but still needs patching
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Near side rear door, not quite as bad as the other thank fully!
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Welding is underway! Front doors are finished, rears tomorrow/Weds, cost is adding up but end of the day a pair of new doors from SP would be £430 + paint so worth it really.

Also popped into Halfords for a rattle can for the external areas to find the have outsourced their paint mixing!!!

To Upol!! :D So that's a nice bonus!

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More progress on the doors, taking a little longer than planned as YRMs Courier didnt deliver the repair section today as they where supposed to! Hopefully it'll arrive tomorrow morning....

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Also got on with sound proofing the door cards, had more than I though so in the end there is more coverage! I was careful to keep the foam away from any of the frame. It's a nice quality neoprene foam, pretty dense so should provide a good level of sound deadening, on top of the door skin soundproofing.

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Doors are all done! With many thanks to the fellas at MC Autocentre! Not too bad price wise either.

Cracked on this afternoon/evening with prepping, painting and soundproofing. Had to grind back some of the welds some more just to get a more flush finish but nothing too difficult!

Sanded any rusty/surface rust/welded areas back, then cleaned, and degreased. Finished off with two coats of Buzzweld CIO and Upol Epsom Green where required

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Upol Epsom Green is a brilliant match!
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Got one coat of LizardSkin on one door, bit the bullet in the end and bought the proper application gun. Which is very good quality, not sure what else it could be used for but I'm sure I'll find something!

Goes on very well, easy to use, similar in application to Raptor but a bit more sputter as you can see! Good thing is, it is super easy to clean up, easily cleans up with some warm water. Second coat will go on tomorrow

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Got 3 doors cleaned, degreased, painted and ready for LizardSkin tomorrow! Had to re-drill the door card mounting points and all the holes for the lower door seals, easy enough to do.

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Once the LizardSkin has two coats (1mm thick) the doors will be left over the weekend to fully cure then covered with 6mm closed cell foam and 3mm foam and finally back on!

While the LizardSkin cures I'm going to fill the doors with Tetrashutz, keep em good for a tad longer!!
 
What was that paint like to use mate? Gotta do those rusty bits on mine in the spring, sure the bit above windscreen lets water in!
 

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The Upol was great! Quality well flowing adjustable nozzle, colour match is very good (would have been better had I used a lighter primer). Quite good value at £17.99/500ml that said I didnt really look anywhere!

Would use it agaib.
 
Second coat finally on! Ended up leaving it to dry over night. Now it'' fully cure over the weekend.

Preliminary results just from tapping the door skin im very impressed! Totally sound deadened, complete coverage and I would say better than Dynamat. Nice solid thud, zero resonance or rattle. Should get the foam layers on early next week.

Eventually I'm going to cover the underside of the seatboxes with a couple layers then two layers of Raptor to protect it. Should make the 110 damn quite on the road!!

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I have four doors! Finally!

Except I have 3 nuts, 2 bolts and 4 screws left over :oops::rolleyes::rolleyes::rolleyes::p

And the central locking isnt working on the pass door but it still locks from the inside, i think I may have forgotten to plug in the actuator! (Ill check that all tomorrow beer now!)

One thing is the doors are quite weighty now! Make a nice THUD when they close :D

Also pics tomorrow!
 
Finally all done! Turns out I hadnt plugged the actuator in! Everything works as it should, door cards are on much better now too, though anyone know how/if you can replace the yellow door card retainers?

Quite hard work doing all this! While the doors where apart I throughly cleaned the glass then treated the outside with Rain-X and the inside with Rain-X anti-fog.

Foam is layers of 6mm closed cell foam glued on with high temp spray glue and weighted down for a few hours, then a layer of 3mm closed cell foam on top of that!

New lower door seals all round fitted with pop rivets and some RTV, hopefully keep some more water out when wading! :) Need to get a few bits like lock plunger surrounds etc.. though not until I can work out how to repair the door cards.

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