Hi Folks,
Yesterday I decided that it was time that I repaired my door bottoms. As it turned out I managed the nearside just before it started to rain, so I guess you're just going to have to use your imagination for the offside...
Picture #1,
After removing the door, and before you start cutting, make sure that you have CAREFULLY un-peeled the ally skin from the frame, so that it doesn't get damaged.
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Picture #2
My corner at the post end was badly corroded, so that would need to be replaced as well.
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Picture #3
Having cut out the bottom rail, I needed to remove the damaged corner back to a good thickness of metal to weld to. I kept the peices that were removed to use them as a rough template to cut the new pieces.
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Picture #4
Remember guys, 'Check your corners' !!
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Picture #5
After much cutting and welding, this was the end result. Needless to say that having cut the original pieces out, it takes a bit of tacking and hammering to get them so the they are straight. Once your happy with the fit, its just a case of welding it up, then grinding down the excess.
Remember that if you have butt welded your edges, and haven't left enough of a gap, when your grind your welds down you are cutting down on the thickness, and strength of your weld. You should always leave a small gap to ensure good penetration.
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Picture #6
Once you've ground your welds down to a nice finish, its time to give your work some protection. ( For you eagle eyes out there, its dark green Hammerite, and not the proper colour. As its going to be on the inside I didn't think it mattered if it was colour coded or not! )
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Picture #7
The corner that wasn't, now is!!
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If you don't try, you never know what you are capable of, and bearing in mind that to replace door bottoms on a Defender will cost around £100-ish its well worth having a go. If you aren't sure about using a welder a couple of days tuition doesn't cost too much, and we all know that it will pay dividends in the long run.
A
