It's galvanic corrosion coming through from behind where the aluminium skin touches the steel frame. You can rub it down, fill and repaint, but it'll still come through again eventually. The only permanent fix is to rebuild the door with some sort of separating layer between the two metals, or...

Looking fantastic. I'm very envious. Only just getting back into working on mine after a two year break. You've definitely taken the lead! I noticed that you've gone for the TD5 rear crossmember on the 200Tdi chassis, which I did too as I preferred the look of it. I wasn't expecting there to be...

Thanks, I feel like I've been out of the loop a bit! I didn't change the resistor, but it looked alright and was working fine when I last used it (in 2009!). Fingers crossed, but it's not a huge job to replace it if it turns out to be knackered.

And two years later, we're getting back into things again. Don't ask! I've rubbed down and resprayed the calipers in proper caliper paint after the Buzzweld High Temperature Silver paint rusted through just sitting in the workshop. Painted and rebuilt the radiator frame with stainless bolts...

At least it's still a galvanised chassis under the paint. That's not great, though bashing a quarter ton engine against the paint is probably more extreme than it'll get in everyday use. I'm a bit envious of your shiny new intercooler. I'm planning to keep my old one as it's not too bad...

It's all looking great there. Hoping to restart work on mine soon after far too long off, but you've definitely stolen a lead on me! Did you run your chassis wiring inside anything to protect it in the end? That's one of my next jobs. I bought a fish wire to pull it through which has been great...

My galvanised chassis is painted with GIO (following a good coating of T-Wash), but as the rebuild has temporarily :rolleyes: stalled it's not been subjected to any real-world conditions yet. However in the not very harsh conditions of a garage it's still firmly stuck on and seems to have...

I spent ages trying to free up my front propshaft slider and although I got a bit of movement back it wasn't smooth. I read somewhere that the splines are coated in something that once gone will prevent it sliding smoothly. In the end I just went for a new front prop as they're not the most...

Great use of a trampoline there! I'll have borrow ours from the kids when the time comes.

The trouble is that Bearmach only discount their own branded products, which is useless if you're trying to stick with OEM where you can. They have these "quick, buy now, our once in a lifetime offer expires in half an hour" sales, then they'll either extend them by a couple of days or have...

It seems Paddocks are having a patriotic St. George's Day 10% off sale today - code SGD2021

Sorry, forgot a photo of the actual hole if that's of any use

OK, turns out I was at a loose end this evening. A bit of dismantling later and the answer is 20mm. The two holes have a plastic sleeve between them of internal diameter 19mm and length 25mm that the shaft passes through, and there's a rubber grommet in each of the holes. If you need any more...

Glad to see you're at the painting stage. Your doors are in a much better state than mine so it'll be a while before I get there! My rear door has a wiper so I'll have a look at the hole diameter next time I'm over at the garage. Might be a couple of days though.

4 months to undo? That's one stuck nut! ;)

Thanks, I'll remember that for next time! Good to see someone else from Anglesey on here. Whereabouts on the island are you?

Looks great. There's nothing so satisfying as getting a coat of paint on. Your wheels have come up a damn sight better than mine did.

Thanks. How's yours coming along? Yes, it's a Shielder. I've heard mixed reviews, but hopefully they've improved their quality control. We'll see.

They had a 10% sale for a couple of days at the end of January. I can't remember the last time they had one - they're not like Bearmach with their insanely regular 15% off 'flash sales', however you can get 5% off at Paddock if you're a new customer with the code WELCOME5, but if you've already...

It's been a slow couple of months where I've had to spend most of my evenings packing boxes to move house, and then unpacking them following the move, plus the house we've bought has turned out to be a bit more of a project than I'd anticipated. Still, I managed to a get a few things done. The...