110 Middle Door Disassembly - Defender Source
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  #1  
Old August 16th, 2010, 04:07 PM
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110 Middle Door Disassembly

Anyone have any tips on disassembling a 110 middle door? I am swapping my all my guts to a new frame. The window crank and associated lock parts look easy, but it's the weatherstripping and stationary window that is perplexing me.

Cheers!
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  #2  
Old August 16th, 2010, 04:12 PM
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yeah-held in by several tiny screws. Suggest getting all new window tracks (cheap and make worlds of difference).
Make sure you use a philipps with a tiny head as they a bitch to drill out.
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Old August 16th, 2010, 04:14 PM
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Thanks, I have a feeling mine are held in by rust. I went poking at my right hand door with a screwdriver to see if I could repair the steel frame and it nearly crumbled to dust.
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Old August 16th, 2010, 04:37 PM
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I did the doors on my 110 not too long ago... it's just a case of remembering where everything went when you dis-assembled it all, and refitting it all back in again.

If you're lucky, all the "spacer" pieces (thin strips of ali) will still be there underneath the felt window runners... this keeps things nice and "tight" (you could also add a thin washer under each screw fixing... between the runners and the door frame) which will stop the windows from rattling "down" as you drive along.
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Old August 17th, 2010, 01:42 AM
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The hard part is just finding all the little screws and an awl helps a lot for that. The vertical channel is a bit of a pain, because it has two bent-over "ears" at the top with a screw in each side, so you have to take the narrow glass pane out first by sliding it down. There is also a fair amount of sealer used around the bottom of the narrow pane and this has to be removed carefully. Echo what Doug said about new channel. If you recycle channel from old doors or something I find the easiest way to cut it is with a dremel cutoff disc so you don't crush the channel.
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Old August 17th, 2010, 10:43 AM
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There are seemingly no directions on how to do this that I could find. The factory manual sucks. My best advice would be to lay out the parts in a sequential way as you dissasemble the doors or label the parts or whatever system works for you. I use zip lock bags and legal pads to keep notes. Its really tempting to bend/tweak things to get them apart and that makes re assembly a nightmare. In my case Charles and I completely wasted the felt lined tracks taking the doors apart but they were rusty and useless. I kept them even though I bought new so that I could see which of the preformed holes were used for screws in the original doors.

Best of luck I'm going to be doing this again in a month or two when I galvanize the back door frames I got from Stephen. I'd rather do a clutch job than mess with intricate door linkages ! @ least the back doors don't have lock cylinders and the associated linkages-pita !
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