 | Home > My Defender > 1995 110CSW Epsom Green to Keswick |
 
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 834   
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The last of the doors is now on and on the plus side I didn't have a series of impromptu showers today.
I did however struggle with the 30 year old bolts through the B pillar and at least one of the hinges only has hinge pin left in one end of the tongue so the hinges were definitely due a change. Out of the four bolts 2 came out with an impact driver, one came out with a stud extractor and the fourth one eat the stud extractor for breakfast and left me scratching my head for a while, thankfully it was on the top hinge so I ended up drilling it out from the rear. The bottom captive nut plate had to be extracted and straightened as using the impact driver on it bent it somewhat and the new bolts wouldn't both find the thread. It is not as much of a nightmare to get to as I was expecting. Anyway you all want to see the photo of the passenger side with both of its new doors so.....  Click image to enlarge There wont be much progress over the next week or so as we are going to be using it for a change instead of working on it. Hopefully the doorcards will go in tomorrow afternoon/evening and if it goes to plan I will put a quick picture up of that ...... as a teaser I will say it involves rivnuts and stainless steel dome head machine screws. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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27th Jul 2025 6:51pm |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 834
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I did manage to get the 2nd row door cards in today with my slightly more industrial plan than the original plastic clips on plastic clips into rubber thingy wotsits.
It turns out the holes in the door for the rubber grommets are the perfect size for M5 Rivnuts. The door cards drill ok with decent drill bits with wood on the face as a backer and drilling through what was left of the plastic bits on the rear. I decided that 7 flanged dome head M5's would be more than sufficient to replace the 12 plastic clips (and one or two bolts would have to be very long for M5's, if they rattle I can always unscrew them and add a couple more here or there. Anyway a couple of pictures. Click image to enlarge Click image to enlarge A couple of the flanges on the hinge side are a bit close to the edge and I may in time pack the back out with some grey epoxy putty if it bugs me too much. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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28th Jul 2025 9:41pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 11052 
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Great work you've done with the new doors
 Clayton.
1996 Golf Blue 300Tdi 110 Pick up. Keeper. |
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4th Aug 2025 3:12pm |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 834
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Thanks Clayton.
This week away is also proving the new auxiliary electrical system and I am pretty sure I can get away with upgrading the 8 or so year old USB sockets for fast charge/USB C PD ones. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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4th Aug 2025 5:06pm |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 834
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Now back from various trips so it was time to get back on the colour conversion.
Spoiler alert nothing has changed colour today... So the chequer plate (a previous owner had a fetish for the stuff) was going to get in the way of painting the wing tops, sills and rear quarters so there was only one solution. This is what it looked like before I took a drill to the rivets. Click image to enlarge And a few of afterwards including I suspect the reason it had Chequer plate sill covers. Click image to enlarge Click image to enlarge Click image to enlarge I was thinking that I may put Rivets in the holes in the sills and then paint them black doing away with the chequer plate but at some point the rear of the drivers side has had some unwanted attention. Click image to enlarge I could by a rear sill section and replace just that part but then it would look odd that it doesn't have the rivets that the other parts have. Another solution is to replace both the sills complete but that wasn't factored into doing this (as other things weren't but became non optional). Alternatively I stick with plan A which was to paint it black and put it back on. Which I already have the paint for and had budgeted for black rivets already. I have no plan to remove the other minor dents that the vehicle has but to leave this one on display is a bit much. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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19th Aug 2025 4:16pm |
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| bodstruck Member Since: 09 May 2020 Location: Wiltshire Posts: 1003
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I needed to replace the sills on my old puma. I bought a secondhand set on ebay for less than £50.
I did away with them on my tdi in favour of rock sliders but if you want to keep the steps and sills perhaps replace the whole lot? https://ebay.us/m/S9xJHo |
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19th Aug 2025 5:32pm |
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 834
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I'm putting the chequer plate back but in black.
Todays progress... The eldest boy pressure washed the chequer plate and took a photo of me decal removing Click image to enlarge And then it was more naked with all the decals removed Click image to enlarge Courtesy of a plastic razor blade handle and blades combined with a removing wheel in a couple of places, it was actually a bit quicker and easier than I thought. Then on to etch priming the chequer plate Click image to enlarge By tomorrow night (weather permitting) the chequer plate will be black and waiting for the body to change colour. 1995 300 Tdi Epsom Green- Slowly Turning into Keswick Green - It's a keeper. Wide Track Sankey- In bits- Gone to a new home M0XQS |
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22nd Aug 2025 5:50pm |
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