Thread: Project Log - Aluminium Tail Door Card Replacement

Originally Posted by fitzy

But they have the possibility to be the work of the devil if they fail then slip and won't undo.
Check twice.

Oh yes! however doing them the you did them (and i did) with 2 spanners etc i like to think that more torque can be applied than with the commercial tool..

Originally Posted by ScotchRocks

Also, I deliberately decided to leave the internal latch in so that if the external handle dies I can clamber over and open from inside. If there is a table in the way you may want to think about an alternative release system mounting location.

Was going to have the cut out in the table aswell to allow for scraps and what not to fall through into a bin

I did actually nearly thread the second one I did, but saved it with careful use of tap.

Originally Posted by DiscoMick

Nice. I've been eyeing Front Runner's fold down table sold through Opposite Lock, so I might have to do the inside of the Defender's rear door myself.

And another old pic for you![ATTACH]

122502[/ATTACH]

Here is mine. Pretty much same process, the only thing I noted is that the door card is not a great template, the foam padding is oversize, so ideally you want the bare cardboard to use as the template. That is why lining up the holes seemed very hit and miss and I had to do a bit of resizing (it was about 2mm oversize when first cut).
I also fitted the bin to the bottom after this, wedged in contents and using a bungie cord it doesn't all fall out when dropped down.
I used basic wire and the after these photos I led it in a loop from all the way around, it makes it neater and doesn't leave knots or swages in sight.
I ended up using gate lock hoops at the top to secure and some pins to drop in.
Used it once or twice and it's quite nice to have. Also got some edging which makes it a bit nicer on the edges as well.
Strength wise, you can make a sandwich and a brew on it, but it feels a bit flexy for heavy duty work.


2016-10-23 18.22.29.jpg2016-10-23 18.23.45.jpg

Both look great.
Is the 'kitchenette' a commercial one or homemade?

....a rear door table is one of the most satisfying mods I've made to my D2
Screen Shot 2017-04-29 at 11.45.52 AM.jpgScreen Shot 2017-04-29 at 11.46.52 AM.jpg
onebob

Originally Posted by onebob

....a rear door table is one of the most satisfying mods I've made to my D2
Screen Shot 2017-04-29 at 11.45.52 AM.jpgScreen Shot 2017-04-29 at 11.46.52 AM.jpg
onebob

That's a great idea for a wash up tub