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OK so finally got around to fixing the door. All done, and painted. Talk about faffing on. Too many hours ****ing around to be honest but got there in the end. Here is a shot of the partly constructed hinge guide made from steel tubing, welded onto a piece of flat bar stiffener which was drilled...

Thanks, I will. Would be handy just to have one as a spare anyway, even this repair does go OK. Won't get back to it now until the new profiled section arrives. I've ordered up a few other bits and pieces (window guide and shim, screws, etc.) may as well do a proper job whilst the bleedin' thing...

It'll probably end up that way, but this is worth a shot before I part with a shed load of cash for a new door. o_O The biggest PITA is the fact that I can't drive the damn thing until I get this sorted :mad:

I might try that. I was thinking that I should weld in the bar first to get a good strong weld, drill it for correct bolt spacing, tack on the tube, drill out the repair section, then sit the repair section on top of it (assuming I can get one with the recessed profile), then weld it all up...

That's the plan. I have some correct size tubing and I'll weld it into the box section - hopefully getting the spacing bang on so that the hinge bolts line up. Problem is how do I get the strengthener bar welded in under-neath it!

I've been on their website - they do some good stuff, maybe they could make up a piece as a one off for the vertical box section. It would probably cost as much as a new door.

Probably been asked before but I can't find anything from searches etc. I've started a repair on the bottom section of the passenger door on my 2001 90 CSW. It should be a relatively straight-forward job...take off door card, prise the door skin away, cut out rotten section, weld in new, job...

Hello folks. This forum seems to be the friendliest, newbie tolerant, and knowledgeable out there - so here I am! I own a 2001 Defender TD5 90 CSW with more than a few 'issues' but hey, that's part of the fun right? Previously owned a 1999 TD5 90 pick-up which was much loved but I needed the...