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Vesuvius



Member Since: 06 Aug 2016
Location: Northumberland
Posts: 17

United Kingdom 
Station wagon conversion troubles...
I recently purchased this superb defender fresh from rebuild and have inherited one or two troubles with it. I am wondering if anyone can come up with some advice on how to best sort out a panel issue...

First of all here is the vehicle side on...



Click image to enlarge



The issue I have is an ill fitting passenger door. Drivers door (this is a RHD vehicle) fits fine.
In this picture you can see my problem. The passenger door slams against the load area side panel. The overlap is a couple of mm.

The door hinge is adjusted to max.



Click image to enlarge



I believe the trouble is due to the rear panel being a few mm too long!

Here is why I think that...

This is the driver door fit... Which is pretty much spot on.



Click image to enlarge





However... This is the rear panel on the driver side... Look closely; it actually overhangs the rear tub by around 4mm.



Click image to enlarge



Now look at the passenger side... There is no overhang and a flush fit. Great for the rear but that 4mm is about the size of my passenger door fit issue.




Click image to enlarge




So the question is... How should I fix this?
My options are...

1. Remove both sides, remove structural bits, refold to 4mm shorter, re drill all holes, refit, paint.
2. Somehow encourage the passenger side panel rearward to match the driver side. In doing so I think I get away with just a few holes reamed out to achieve some adjustment.

Is there some other possibility I've not considered?
Post #554514 8th Aug 2016 4:01pm
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apachecow



Member Since: 12 Apr 2016
Location: Yorkshire Dales
Posts: 59

1999 Defender 110 Td5 CSW Rutland Red
Have you tried a block of wood and a couple of taps with a hammer?
Post #554515 8th Aug 2016 4:05pm
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pj2106



Member Since: 20 Dec 2012
Location: Huntingdon AKA The Shire
Posts: 1500

United Kingdom 2008 Defender 110 Puma 2.4 USW Stornoway Grey
Try adjusting the door hinges they do have some movement 2008 110 2.4 XS Utility (Hagrid)
2002 90 TD5 Hardtop (Sully) Sold
1998 300TDi D1 (Billy) Sold
Post #554517 8th Aug 2016 4:09pm
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Vesuvius



Member Since: 06 Aug 2016
Location: Northumberland
Posts: 17

United Kingdom 
Hammer and block has not been deployed yet!

Door hinges are maxed out.

My hope is that I can slot the bolt holes and achieve that precious 3 to 4mm that way but it isn't precision defender owning as I had imagined it!
Post #554527 8th Aug 2016 5:15pm
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apachecow



Member Since: 12 Apr 2016
Location: Yorkshire Dales
Posts: 59

1999 Defender 110 Td5 CSW Rutland Red
I've seen worse fitting back doors on brand spanking new ones.....
Post #554528 8th Aug 2016 5:27pm
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CarMan



Member Since: 29 Nov 2010
Location: Cotswolds
Posts: 1767

United Kingdom 
Sorry for your stress and I can't help at all, but lovely looking truck in a fantastic colour Thumbs Up Rob

1993 200tdi 90 hard-top
1998 300tdi 90 soft-top
2016 2.2 XS 90 hard-top
Post #554531 8th Aug 2016 5:31pm
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Vesuvius



Member Since: 06 Aug 2016
Location: Northumberland
Posts: 17

United Kingdom 
Thanks all.

Will report back after trying the block of wood.
Post #554536 8th Aug 2016 5:47pm
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davew



Member Since: 02 Jan 2012
Location: North Yorkshire
Posts: 888

England 1990 Defender 90 V8 Petrol PU Auto Rioja Red
There's quite a lot of adjustment available in the standard bolts. Defender body panels have never been particularly accurately built so they are built with that in mind. You'll probably find that if you loosen off all the bolts on the side panel, top and bottom, you'll be able to move it far enough backwards.

There is also some scope in tilting the bulkhead forward and lifting the front of the back body but only go down that route if you have a LOT of patience and a bad case of OCD. Lining up Defender bodywork is all about finding the best compromises between the panels. http://www.yorkshireoffroadclub.net/
Post #554537 8th Aug 2016 5:58pm
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10355

United Kingdom 
As Dave said, it's doable, but it will be a case of a lot of loosening bolts and lots of help with friends, as you move stuff to fit, get somebody tightening things.
There's 2 brackets that come off the bulkhead and go forwards and mount on to the chassis, these have lots of adjustment with 'long holes' ( the technical word I don't know Embarassed ) and you can move things around.
It's all a bit tricky!

I'd move the side panel back inline with the tub, and work from the bulkhead, then there's a surprising amount of movement in the 4 holes of each hinge Thumbs Up
Post #554542 8th Aug 2016 6:49pm
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Vesuvius



Member Since: 06 Aug 2016
Location: Northumberland
Posts: 17

United Kingdom 
The job is underway.

Loosening bolts wasn't enough. I've removed everything in the hope of seeing a bit more willingness to move...

The issue I have now is the gasket between tub and sides (thick foam one) seems to have a pretty strong grip on things.

I can't get any lateral movement in the side panel at all.

I think I'll strip more bolts to loosen the roof and then that should relieve some pressure.

I'm getting mobbed by midges so will continue a little later. __________________________
I've got previous...
2004 DCPU Td5 - GKN overdrive, warn winch, truck man canopy
2005 G4 D3
2012 D4 HSE
2013 D4 HSE
Post #554560 8th Aug 2016 7:41pm
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Guy



Member Since: 11 Feb 2013
Location: St Eval, Cornwall
Posts: 250

United Kingdom 
I remember seeing that beast for sale. What a beauty! Hope you get it sorted. 
DINGO - '99 Discovery 2 V8 with 300Tdi transplant, chawton white. Repatriated from Australia and expedition prepped.
**FOR SALE**
SHARKY - '06 Discovery 3 HSE Auto, bonatti grey. SOLD.
GEORGE - '99 Discovery 1 300Tdi Auto, willow green. Daily driver, travel companion, part of the family! SOLD.
PINGU - '96 Defender 110 300Tdi station wagon. SOLD.


Dream LR - 130 pop top station wagon camper.
Post #554612 8th Aug 2016 10:01pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

England 2004 Defender 110 Td5 CSW Bonatti Grey
Could you not take it back to where you bought it for them to fix? Ray
My build thread
http://www.defender2.net/forum/topic17615.html
Post #554621 8th Aug 2016 11:59pm
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Vesuvius



Member Since: 06 Aug 2016
Location: Northumberland
Posts: 17

United Kingdom 
Private sale. I knew about the commissioning issues!

It's definitely just misaligned - needs more encouragement than I can give it on my own so I'll try again when I have some help on hand. __________________________
I've got previous...
2004 DCPU Td5 - GKN overdrive, warn winch, truck man canopy
2005 G4 D3
2012 D4 HSE
2013 D4 HSE
Post #554648 9th Aug 2016 7:16am
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Vesuvius



Member Since: 06 Aug 2016
Location: Northumberland
Posts: 17

United Kingdom 
So the side panel has been moved aft. I now have reasonable clearance.

The door, however is not square with the panel.

The only explanation I have heard is that the bulkhead may be misaligned.

The somewhat avant garde rakish angle of my bulkhead does at least mean I probably have the most aerodynamic 130! __________________________
I've got previous...
2004 DCPU Td5 - GKN overdrive, warn winch, truck man canopy
2005 G4 D3
2012 D4 HSE
2013 D4 HSE
Post #554855 9th Aug 2016 9:10pm
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Welkman



Member Since: 02 Nov 2014
Location: Essex colchester
Posts: 326

United Kingdom 
Same issue for me in my 110. I undid the roof, sides and used some ratchet straps/persuasion to improve things. I do however think that the bulkhead is no fitted properly so if I ever rebuild I will be able to satisfy my OCD but I am happy to live with it for now.
Post #569610 9th Oct 2016 9:22am
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