Doors: rebuild or replace?

MonLand

Active member
Is it worth it to rebuild doors (metal frame replacement or bottom portion repair) or not worth the time and money (as I would not be doing the work)? The skins are ok with some corrosion in the bottom corners but no too bad.
 

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4RF RDS

Well-known member
Likely end up paying about the same. When there is aluminum corrosion already, that means holes in the alu, you won’t get rid of it, as in it’ll just come back in the same spot. New is likely your best option. 🤷‍♂️
 

Grnrvrs

Well-known member
I rebuilt the doors on my '83 110. They are the rare-ish split top doors. The frame channels are the same as series trucks, rather than the later defender profile. After the welding work, I had them hot dipped, then I reskinned them with new skins. At the time it was the only option other than new (2010ish doors) or series doors. Zero corrosion in the last decade or so. IMO, it all depends upon your budget. Whatever you do, I suggest that you make your choice such that you end up with doors that won't corrode like the original stuff. While I have never dealt with them, the sp-4x4 galvanized stuff looks appealing.
 

mgreenspan

Founding Member
Some things for you to ponder:

1. How long are you planning on keeping the vehicle? Goes for both even worrying about the repair in the first place and which type? Rebuilt and galvanized the way lots who do their own rebuilds do makes sense if you plan on keeping the vehicle until you no longer drive. New vs repair? I’d say if you’re not planning on keeping the vehicle past 5-10 years just throw newer type on and forget about it. Keeping it forever then rebuild them with that in mind. Even bothering to repair/replace might not be worth it based on casual observation of lots owning these for 1-2 years before they move on to another one or something else.

2. Frequency of and purpose of usage? If this lives in a garage and is used once a weekend around town plus the odd trail there might not be a point in bothering. If it never goes out in inclement weather and stays dry just live with it maybe. Add some anti rust treatment to the channels and call it good. Doors and the repair aren’t cheap.

3. Fifty percent of the Land Rovers I’ve owned have been surplus/second/third/project vehicles where I generally did everything myself. Part of my purpose in owning was to wrench on them. I’d do this as a personal project eventually and just deal with the occasional rust vacuuming where I regret my life choices as I hear the rust bits pinging around the inside of the vacuum.

4. Just look at the cost to replace and paint match and consider what else you could buy for the vehicle or how many years of college you would rather pay for a child/family member or a vacation you’d rather go on… or even a really nice used car to wail on. I never achieved perfect doors on any of my 90s or 110s. None were terrible, but never warranted moving up on the list of things to address.
 
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