Defender replacement door cards/door trim

[GCLRL]

Hi all,

First post in here so bear with me if this is in the wrong place.

I have an '04 Defender 110 and the front 2 door cards are shot. I have looked at replacing with factory ones but they are either ridiculously expensive (if new) or not in very good condition if second hand.

I have been playing with the idea of having some fabricated. Fibreglass was the first idea that came to mind then after reading an article in 4WD where they showed aluminium replacement it got me on to that idea!

Only problem is that it is a horrible shape to copy!

Anyone been through this? Got any templates/plans/ideas?

Cheers,

Phil

[juddy]

I maybe able to help. PM me...

[wrinklearthur]

Hi Phil

Welcome aboard to the forum.
I would be interested to see what you come up with for the replacement door cards.
To say hi to the other forum members, get yourself on the Introductions and say hello on there .
.

[tonic]

If you have a good look around the net you will find them pre made in checker plate.

Sorry, cant remember where I saw them, most likely a UK Site, start with Famous Four or Padocks.

[CraigE]

Not sure aluminium or chequer plate would be a good idea in Australia, especially in the Northern, Western or Central areas. They would get damn hot to the point where you could burn yourself quite bad.
Though having said that I would use it if I built a Tomb Raider Replica.
The odd shape makes them quite difficult to replicate.

[flagg]

I have been thinking about the same thing. I've got a chequer plate rear door and I would not want it on my side doors as it increases the noise level significantly.

I've been thinking of a strong plastic covered with a marine carpet, a proper place to put my arm and some map pockets.

There are some around in the UK if you look, but they are just plastic and the shipping prices them out of my range.

If there is someone on the forum who works with plastic of this size.. I'm sure they could get a good run going!

[kelvo]

No idea if they ship to Oz but worth asking MPS 4x4 Store Catalogue (http://dca.dominohosting.biz/dca/mpsdb01.nsf/MainCatalogue%21OpenForm&RestrictToCategory=90_110:%20INTERIOR%20TRIM)

[GCLRL]

thanks for all the tips.

I did think that aluminium would be too warm but as mentioned above noise would definitely be increased too.

Plastic is a great idea but I have called around and making something that big would be pricey.

Just spoken to a mate who works in boat repair and he recommended either moulding the current shape and making fresh ones out of fibreglass or 'skinning' by simply covering the existing card with carbon fibre matting. I like this idea because you could add different shapes add armrests etc.

[Didge]

Would it be possible to use the old ones or similar and use them as the mould for vacuum forming some new plastic ones? That way you'd get (or should get) the same size and shape as the original.