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Bubbly defender rear door

Discussion in 'Defender 90 / 110 / 130' started by Corfewoodsman, May 16, 2020.

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  1. Corfewoodsman

    Corfewoodsman Member

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    Being a captive of the current situation, and busying myself on Defender jobs, I find that I am running out of things to do on it.
    Perhaps the one remaining task is to do something about its rear door.
    About 10 years ago I applied adhesive chevron markings to it and for the last few years have noticed increased bubbling showing through this surface. It is particularly bad along the bottom and around the recessed handle area. I would guess that this is the result of some chemical reaction between the steel frame and aluminium sheet aided by condensation or water ingress. I have a phobia about oxidation, particularly where my Landy ins concerned, and am usually aggessive with it.
    I am sure I'm not alone in having this problem and wonder whether anyone can suggest a remedy.
    My instinct is to strip off the luminous covering, attack the bubbling areas with an angle grinder, fill with pudding and re cover with new adhesive (not magnetic!) markings.
    I wonder whether this would be effective or whether the problem will quickly come back.
    I would really like to hear how some of the Landyzone community have dealt with this problem.
    I am mindful that the vehicle is not young, 1991 though in good shape, and that even Defenders are not immortal so the cure need not last for decades.
    Anyway, if you can help,I'll be most grateful.
     
  2. tottot

    tottot Well-Known Member

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    Get a new door, a whole less trouble. Have you looked at the frame inside? I repaired my 1990 one a couple of years ago and half way through the job wish I had not bothered. Took a lot of time.
     
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  3. Jonmlb748

    Jonmlb748 Active Member

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    You can buy steel replacement bottom half of the door and paint frame and inside of door before fitting with sika or similar .its on the cards for mine after recently filling and painting the aluminium and its bubbled up all ready
     
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  4. lynall

    lynall Well-Known Member

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  5. Corfewoodsman

    Corfewoodsman Member

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    Tottot,
    Thanks for your advice. That is certainly the most elegant solution.
    I've worked on the frame a while back and it is now rot free and heavily reinforced. The problem is more cosmetic, and annoying, than structural.
    I shall probably rip into it before going down the route you have suggested.
    Once more thanks for your help.
     
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  6. Corfewoodsman

    Corfewoodsman Member

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    Thanks for that Jon (Jonmlb748) you have confirmed my worst suspicions of the fill and cover plan.
    I shall still attack the areas and see where to go from wherever it takes me, and will look at all options then. I may well follow your course.
    Sorry to learn of the return of bubbling to your vehicle; Defenders aren't for quitters are they?
     
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  7. Corfewoodsman

    Corfewoodsman Member

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    lynall,
    Thanks for your guidance. I'll look at that with interest.
    You are so right about rust. I've been tying to batter it into a coma ever since I bought mine.
    Thanks again.
     
  8. Jonmlb748

    Jonmlb748 Active Member

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    Kind of expected it. When things get back to normal I will order a steel panel from s&p ,as you say it’s mostly a cosmetic issue but It looks a mess.
     
  9. lightning

    lightning Well-Known Member

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    I fitted a new door to ours.
    Against some advice l used a Britpart one, and l have to say it’s superb.
    Fitted perfectly and is indistinguishable from the OE one.
    As to how long it will last, l don’t know. But it’s been thoroughly treated against corrosion.
     
  10. Corfewoodsman

    Corfewoodsman Member

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    Thanks Lightning,
    Sounds a good way forward. I'll look into that too.
    I've not had a problem with Britpart either.
     
  11. Jonmlb748

    Jonmlb748 Active Member

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    Was it steel or aluminium?
     
  12. tottot

    tottot Well-Known Member

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    Given you have already done the structural work then a new skin insulated from the frame by sealer is the way to go. Thinking of the same thing but not got around to it.:)
     
  13. Corfewoodsman

    Corfewoodsman Member

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