Tomhorner1 · Oct 26, 2019

Hi everyone I bought a defender 90 few months ago, she’s on galv chassis and bulkhead. I have stripped her and had her fully repainted. The doors were past there best so I put 2 new front doors on and a new rear door from paddocks.

I have since had rust bleeding out the tail gate and starting to leave rust marks where the rusty water is running out! Anyone had this before? Where does the water drain from that goes into the pocket where rear door handle is? It’s as if the box section is filling up with water inside and running out the bottom of the door

tottot · Oct 26, 2019

Check that drain holes in bottom rail are open or even there, been missing on some I have seen.
If not already done get lots of wax type preservative inside.

Tomhorner1 · Oct 27, 2019

Thanks, can’t see any in there has anyone got any photos of where they are meant to be?

Al2O3 · Oct 27, 2019

IIRC the rear door doesn't have any. The problem is the 'new' door frames just have a basic layer of paint on them (possibly just primer) before the skins are put on. Water does leak down through the handle aperture, runs down the inside of the skin and settles between the frame and the skin. The frame then begins to rust very quickly.

EDIT
If your rear window isn't sealed properly it can leak through there too.
In theory, water shouldn't get in to the door. So, it doesn't need drain holes.

Tomhorner1 · Oct 28, 2019

Thanks for your help, looked on my old door, no drain holes on there either, back window seems good as it was already installed in the new door so can’t imagine that leaking! going to drill couple small drain holes in bottom of the box section of the rear door and put some wax oil in there!

Tomhorner1 · Oct 28, 2019

Can see some light rust marks on the back door!

Al2O3 · Oct 28, 2019

Tomhorner1 said:
Thanks for your help, looked on my old door, no drain holes on there either, back window seems good as it was already installed in the new door so can’t imagine that leaking! going to drill couple small drain holes in bottom of the box section of the rear door and put some wax oil in there!

Try sealing the door handle first!
You could try sealing between the door frame and the skin to stop the water getting in the gap.

lynall · Oct 28, 2019

Looks to me like door lock might be the culprit?

Al2O3 · Oct 28, 2019

lynall said:
Looks to me like door lock might be the culprit?

Me anorl. But, the windows are trickier to seal than you might expect. I'd be gently running a flow of water over it from a hose pipe and looking for signs of ingress from lock/handle recess and window surround.

tottot · Oct 28, 2019

Drill holes in each end of the bottom rail and fill with lots preservative is what I did . There should be a plastic surround on the door lock.

zeaphod · Oct 29, 2019

They all do that sir...

Tomhorner1 · Oct 29, 2019

Had a go at it today, firstly drilled 2 holes in the bottom of the box section on the door at opposite corners, lots of rusty water came out!! Amazing how quick it has turned for a new door only been on there just over a month! I sprayed once it dried with wax oil the aerosol in to try and get some protection on the inside. Tried a hose pipe over the door with it shut and the door lock was leaking so I removed this and have put some sealant behind it then re assembled it so hopefully should be a lot better now will keep you all updated

Al2O3 · Oct 29, 2019

Tomhorner1 said:
Had a go at it today, firstly drilled 2 holes in the bottom of the box section on the door at opposite corners, lots of rusty water came out!! Amazing how quick it has turned for a new door only been on there just over a month! I sprayed once it dried with wax oil the aerosol in to try and get some protection on the inside. Tried a hose pipe over the door with it shut and the door lock was leaking so I removed this and have put some sealant behind it then re assembled it so hopefully should be a lot better now will keep you all updated

How is the water getting inside the frame tube?

Tomhorner1 · Oct 29, 2019

Looks like when it runs out the door lock it runs down the skin on the door and into the tube..

Al2O3 · Oct 29, 2019

Tomhorner1 said:
Looks like when it runs out the door lock it runs down the skin on the door and into the tube..

Is the tubular frame, inside the door lock square panel, open so water can get in?

Tomhorner1 · Oct 30, 2019

there's a little drain hole in the corner which when we wet the back door the water stated coming out of around the lock then out of the drain holes we drilled in at the bottom of the door

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