Door alignment rebuild

turrican · Sep 26, 2019

So I've spent a good few hours trying to get tub, bulkhead etc... lined up so door gaps are good. I've come to a point where I can't seem to get it any better. I've got new genuine door hinges and got same distance between top and bottom of bulkhead to tub, also used string to get tub curve aligned with bulkhead curve.

The problem is the van sides seem to taper inwards and the curve on the door doesn't line up with he bulkhead.

Do I give up on trying for perfection as it's 25 year old defender, or should I battle on?

Picture showing state

K14 · Sep 26, 2019

I spent ages like yourself looking for perfection. I found it wasn’t possible lol

Pappasmurf · Sep 27, 2019

Mike at Britannic restorations, on YouTube, did a few videos on door alignment. Very useful.

https://www.youtube.com/channel/UCRssffMP_F8_SCJcqFLq4Ow

turrican · Sep 27, 2019

Pappasmurf said:
Mike at Britannic restorations, on YouTube, did a few videos on door alignment. Very useful.

https://www.youtube.com/channel/UCRssffMP_F8_SCJcqFLq4Ow

Yep have watched all his videos, followed them as closely as I could. Just thinking that working with a new chassis and galvanized bulkhead I might be fighting a battle I cannot win.

Pappasmurf · Sep 27, 2019

That maybe the case. If everything g else is perfect, perhaps it's your doors that are the problem.

turrican · Sep 27, 2019

That's a good point, I will look at the doors in more detail.
I am going to have another go, I'm happy with the gaps but I don't like that the arch/curve doesn't line up.

mick the builder · Sep 27, 2019

Looks like baulkhead needs moving to the rear a bit at the bottom. This would lift lock side of door and equalize the gap.

turrican · Sep 27, 2019

mick the builder said:
Looks like baulkhead needs moving to the rear a bit at the bottom. This would lift lock side of door and equalize the gap.

Yep I think you're right, at the moment the top and bottom of the bulkhead is equal distance.
I'll align everything using the door instead of taking measurements and see how it looks.

turrican · Sep 27, 2019

So there was a bit of vertical play in the door hinges and removing some spacers to allow the bulkhead tilt forward a little bit seems to have aligned the arch. That's one side sorted...

Thanks for everyone's help so far

Al2O3 · Sep 28, 2019

Was that spacers on the bulkhead to chassis brackets in the engine bay or out rigger. Just thought I'd mention those. Haven't watched the videos!
That door looks great now!

turrican · Sep 28, 2019

Al2O3 said:
Was that spacers on the bulkhead to chassis brackets in the engine bay or out rigger. Just thought I'd mention those. Haven't watched the videos!
That door looks great now!

It was the spacers on the bulkhead to chassis in the engine bay.

mick the builder · Sep 28, 2019

turrican said:
So there was a bit of vertical play in the door hinges and removing some spacers to allow the bulkhead tilt forward a little bit seems to have aligned the arch. That's one side sorted...

Thanks for everyone's help so far

Looks perfect to me.

turrican · Sep 29, 2019

It turns out the gap was a little too big, when I tried door seal there where a couple of places where I could see daylight. The gap was around 15mm, so with a bit of adjustment I managed to get this down to about 10mm which works well with the door seals.
From the information I've read the gap should be somewhere between 7 and 11mm.

Pappasmurf · Sep 29, 2019

I hope I can get my gaps that good after my doors are refurbed and new sills fitted.

mick the builder · Sep 29, 2019

turrican said:
It turns out the gap was a little too big, when I tried door seal there where a couple of places where I could see daylight. The gap was around 15mm, so with a bit of adjustment I managed to get this down to about 10mm which works well with the door seals.
From the information I've read the gap should be somewhere between 7 and 11mm.

Even more perfect. .

mick the builder · Sep 29, 2019

What's your gap at the top like? Mine is quite large but if I raise the door, I'm in the same position as you regards the curves lining up. It's as if the doors top rail is too narrow.

turrican · Sep 29, 2019

I've got a gap about 12mm at the top of both doors. Pic attached.
How big is your gap? My tub was tilting down, I had to put spacers under the pads at the seatbox end to get it aligned. I used a piece of string from the rear of the tub to the bulkhead at the arch to make sure it was level.

mick the builder · Sep 30, 2019

turrican said:
I've got a gap about 12mm at the top of both doors. Pic attached.
How big is your gap? My tub was tilting down, I had to put spacers under the pads at the seatbox end to get it aligned. I used a piece of string from the rear of the tub to the bulkhead at the arch to make sure it was level.

I've got 12mm on the outside. I remember now before I fitted the door rubbers I could see through the gap. My problem now is the gap at the bottom. I dont really want to pop rivet the cill rubber through my new frame. I'll live with the gap.

turrican · Oct 1, 2019

mick the builder said:
I dont really want to pop rivet the cill rubber through my new frame. I'll live with the gap.

I've contemplated something like this along the sill, not sure how long it would last but its cheap and doesn't require any drilling.
https://www.screwfix.com/p/stormguard-extra-thick-weatherstrip-black-3-5m-2-pack/40425?

mick the builder · Oct 1, 2019

That's reminded me I bought some self adhesive neoprene rubber strip from Ebay to put under my floor panels. Comes in various widths and thicknesses. Cheers.

Door alignment rebuild

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