Rusty cab doors solution?

Post by **Stesaw** » 11 Dec 2019, 23:34

Hey all,

As this is the first winter of ownership I've been going through a lot of jobs on our van I've got around to looking at getting to insulation and sound deadening.
However, when we got the van the seals around the windows on the cab doors were pretty bad and it looks like it's been letting in water for quite a while.
I've since replaced the worst of the seals but both doors have blown out at the bottom.

Obviously I want to get the doors into a condtion where I can put sound deading and insulation into the cab doors, My question is for those who have had this problem, how have you gone about repairing the doors?
The only repair panels I have found are for the outer skin, I haven't found any repair panels for the inner underside parts.
Is it a case of going out getting some sheet metal and a lot of cutting,welding and swearing? or am I just not looking in the right places? my sliding door also needs the lower section replacing, but I know what replacement bits to get for that.

As for insulation I've done a bit of looking around and on the wiki already https://www.deadening.co.uk/products/ca ... altion-kit" onclick="window.open(this.href);return false; what are your thoughts?

Post by **Ant-t** » 13 Dec 2019, 09:20

You guessed right with your cab doors, you'll have to go down the "cutting,welding and swearing" route

Post by **Dobble** » 13 Dec 2019, 11:06

This is what I done with mine

https://ben6738.wixsite.com/syncrovanli ... insulation" onclick="window.open(this.href);return false;

Post by **davidoft1** » 13 Dec 2019, 11:11

Used doors are pretty cheap and not difficult to find, unless it’s very minor I wouldn’t weld them
Up

Post by **Stesaw** » 13 Dec 2019, 13:51

davidoft1 wrote:Used doors are pretty cheap and not difficult to find, unless it’s very minor I wouldn’t weld them
Up

I've looked for spare doors but as it's a fairly common problem the ones I keep coming across have the same issues as my current doors.

Dobble wrote:Re: Rusty cab doors solution?
by Dobble » Today, 11:06

This is what I done with mine

https://ben6738.wixsite.com/syncrovanli" onclick="window.open(this.href);return false; ... insulation

Nice, looks great afterwards, was it that much of a pain in the ass to do?

Post by **Dobble** » 13 Dec 2019, 14:08

It wasn't too bad to be honest. It took 2-3 hours from removing the door to being ready to paint. It's a little awkward in places with the curves but I managed it all without any specialist fabrication tools.

Post by **Stesaw** » 13 Dec 2019, 23:03

Dobble wrote:It wasn't too bad to be honest. It took 2-3 hours from removing the door to being ready to paint. It's a little awkward in places with the curves but I managed it all without any specialist fabrication tools.

Well that gives a bit of hope for me, but I guess I need to really have a good look to see how far gone my doors are, then I gotta pick up a decent cheap..uhh budget welder. yeah I know that's wishful thinking.

Post by **Ant-t** » 14 Dec 2019, 01:31

I wanted to replace both of mine but could only find doors with similar rust issues at the time. I ended up replacing the lower outer skins on both and rebuilding the lower part where the water sits above the wheel arch on one. It wasn't too bad to complete, I took mine off to work on them one at a time.

Post by **Stesaw** » 15 Dec 2019, 23:19

Ant-t wrote:I wanted to replace both of mine but could only find doors with similar rust issues at the time. I ended up replacing the lower outer skins on both and rebuilding the lower part where the water sits above the wheel arch on one. It wasn't too bad to complete, I took mine off to work on them one at a time.

Yeah I think that's what I'm going to have to do. Just a bit of a pain in the a*** because I need to sort that before getting on with other work..