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| MarkBrown Member Since: 03 Oct 2022 Location: Mid Wales Posts: 540   
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Whatever you do with the paint, make sure you buy galvanised doors, unless you want to do it all again in twelve months! 1983 110 automatic OM606
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6th Jun 2025 10:22pm |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 759  
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The plan is for galvanised frames with ally skins as they were originally. I've not been overly impressed with zintec finishes on things in the past and as long as the aluminium and galvanised parts are bonded properly they should last quite well. 1995 300 Tdi Epsom Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home M0XQS |
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6th Jun 2025 10:29pm |
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| julian Member Since: 17 Feb 2017 Location: Devon Posts: 174 
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Epoxy primer (others will say etch, but we live in the future now...) and then either a single stage 2k top, or, if you've got one of those glossy trucks, base and clear.
Some would say you should use mordant before the primer. I spray alloy for work all the time with lechler, and the datasheet of that certainly says it's good for fresh zinc without mordant. I've recently followed the datasheet for a door frame that I've just got hot dipped, but it's too early to conclude either way as to if mordant would have been a good idea or not. The primary reason I didn't use it is that I didn't want acids / fluids in the box section. I mean I know it will get wet in use but at the moment I didn't want to risk residual acid. |
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7th Jun 2025 12:57am |
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| landiedave Member Since: 14 Mar 2013 Location: Welsh Marches Posts: 59 
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where are you getting your doors from, sadly I'm in need....
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7th Jun 2025 9:38am |
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| julian Member Since: 17 Feb 2017 Location: Devon Posts: 174
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Personally, im repairing my existing ones, and then getting them dipped -
 Click image to enlarge Click image to enlarge The tunnel and the peddle box were just blasted, but i ran electrolysis (bottom of a cut down IBC) on the frame before dipping to remove as much of the junk inside the box section as possible. Ive got another 5 or so to do, hence wanting a "method" rather than a credit card bill! : ) |
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7th Jun 2025 9:46am |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 759
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Almost certainly SP4x4 as they seem to be the best bet and generally more recommended than others. 1995 300 Tdi Epsom Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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10th Jun 2025 8:50am |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 759
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I thought about repairs but being 30 years old not sure I like the chances of getting the ally skins off complete and really need them to come off and go back on the same day as I don't have a garage or enclosed space I can leave the old girl with a door missing. Some of the iron oxide is also not in the best places to weld new bits into either  1995 300 Tdi Epsom Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home M0XQS |
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10th Jun 2025 8:53am |
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| miker Member Since: 13 Sep 2015 Location: Surrey Posts: 1781 
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Works great, but last I checked you cant do rust removal on the air where steel used to be  |
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10th Jun 2025 10:27am |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 759
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Or where the previous welds are no longer connected to what they were repairing as there is fresh (moot point in a leaky defender) air. 1995 300 Tdi Epsom Green - It's a keeper.
Wide Track Sankey- In bits- Gone to a new home M0XQS |
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10th Jun 2025 10:30am |
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| julian Member Since: 17 Feb 2017 Location: Devon Posts: 174
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In my photo, the entire bottom rail of the frame was air, as well as some way up the sides. Further air was present in other areas. Door frame was originally welded up out of sections, by a human. Door frame was subsequently welded up, out of sections, by a human. But, sure, these things can be fixed with a credit card also. |
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10th Jun 2025 10:34am |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 759
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In an ideal world I would repair them but I don't have the facilities in terms of suitable workshop space to keep her while I am working on the doors
Someone may end up getting some bargain priced repairable doors after I am done though. 1995 300 Tdi Epsom Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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10th Jun 2025 10:40am |
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| julian Member Since: 17 Feb 2017 Location: Devon Posts: 174
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I wasn't being critical. I just didn't understand the "air" comment as welding old cars is always replacing air with metal.
My work is in non ferrous metal, so I'm slightly better placed for this kind of stuff. And, in truth, if I won the lottery, maybe I'd just buy new! (But, possibly, I would not, as, without having to earn money, then I would have more time to do what I wanted!) |
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10th Jun 2025 10:52am |
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