Jump to content

thatnorwegianguy

New Faces
  • Posts

    1
  • Joined

  • Last visited

Everything posted by thatnorwegianguy

  1. Came over this thread via Google and managed to dig the photos out from the Wayback Machine (it stores old websites). Here's the link: https://web.archive.org/web/20170109043226/https://forums.lr4x4.com/topic/55697-replacing-defender-body-cappings/ Images with original text: You will need some replacement body cappings obviously. You will also need some basic tools: Drill & 6mm drill bit, hammer, rivet gun, assorted screwdrivers, pliers, 10mm & 13mm spanners, and a 10mm socket / ratchet. WD40 or similar is useful if some of the fixings are rusty. You will also need plenty of new rivets, I think 60 is enough. To begin with, you will need to remove the headlining, so sun visors and mirror needs to come off. Then remove the 6 10mm bolts which hold the front of the roof to the screen surround. I then removed the rear door hinge from the rear body (13mm). I then removed the 4 13mm nuts which hold the body to the tub. I then removed the 10mm nut and bolt on either side of the tub. Next, I pulled the door seals away from the body. Now, because I was on my own, there was no easy way of lifting off the roof completely. Therefore, I kinda had to bodge it, i.e. supporting the roof with blocks of wood, while i got the cappings off. I don’t have any pictures of the first side, as I was trying to work out how to do it myself : ). Here you can see the old capping removed. You can see clearly why they needed replacing. Here, the new capping is in place, ready to be riveted on. This is how the roof was supported. Now, onto the other side. This one was even worse. Make sure all the bolts are undone, and lift the body clear of the tub. Then undo the angled bracket which supports the rear body. You then need to drill out all the rivets which hold the capping in place. There are about 25 for each capping. Once you have removed all the rivets, it is a case of levering the old capping off; this is easier said than done. I used a flat head screwdriver, chisel and hammer to remove it. Eventually, it will let go, and the capping will come loose. The next job is to remove the remains of the rivets; I used a drill in some cases, and a screwdriver / hammer in others. When you have removed all of the rivets and cleaned up the body, you can slide on the new capping. One useful thing to do, is to put all the rivets into the holes, before you start to ‘pop’ them; this means if the capping distorts slightly when you ‘pop’ the rivets, you won’t have difficulty trying to put the rivets into the holes. Once it is secured, it’s simply a case of putting the body back on. It’s not hard, but will take a bit of jiggling to get everything lined up. Make sure you put on the angled brackets by the rear door first. Once the body is sitting correctly, tighten the corner bolts, and add the bolts for the side supports. Then bolt the rear door hinge back onto the body. Put the door seals back in place, and make sure all the doors shut ok. Below you can see the finished result.(I ran out of rivets right at the end, so there are a couple missing :(. I will fix this tomorrow.) I started at 9, and had all the tools packed away by 5. Now I know what to do, I’m sure I could knock a few hours off next time. Not that I’m planning on doing this again for a while...
×
×
  • Create New...

Important Information

We use cookies to ensure you get the best experience. By using our website you agree to our Cookie Policy