 | Home > My Defender > 1995 110CSW Epsom Green to Keswick |
 
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| 300TDi CSW Phil Member Since: 03 Apr 2016 Location: Bracknell Posts: 824   
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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: 824
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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: 11043 
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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: 824
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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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