Doorbeam replacement.

dpr59 · Post by **dpr59** » Mon Jun 19, 2006 14:22

I intend to start this weekend on the passanger door beam.

Has anyone, having done this, a step guide once the door has been removed.

Order for taking apart / reassembly.

Problematic areas I'm likely to encounter.

Getting it back on, are the bolts that hold the hinges to the body just that.
Bolts into uprights, or nuts and bolts that need to be attacked from both sides.

I'd hate to hear a nut fall into the void of the footwell.

Any guidance would be great.

I'll try and get some shots that I can post for future users.

amarshall · Post by **amarshall** » Mon Jun 19, 2006 15:13

Spare pair of hands available here if you need them - might need a hand with my pod in return though

The worst bit will be realigning the assembly if it drops after the door has been reassmbled. Dan and I devised a method using sockets, spanners and a trolley jack.

Also - BEFORE you start, check the condition of your window frames...one of mine needed some welding before it could be reused.

P.S. - did you remember to get a new hinge pin while you were at it ? If the old one is seized it probably won't be re-usable.

amarshall · Post by **amarshall** » Mon Jun 19, 2006 16:26

Oh, and : http://www.lotusexcel.net/phpbb/viewtop ... =door+beam

dpr59 · Post by **dpr59** » Mon Jun 19, 2006 19:56

Just had a telephone converstion with Mike Taylor who has provided a few pointers.

Printed out the 'Archive' link above.

Charged camera battery.

Now it's time to utterly goose the car......

The replacement beam should be here this week so I'm still on for a weekend of fun and laughter.

Oh, and for good measure the eldest wants me to hang a couple of new bedroom doors at his house.

dpr59 · Post by **dpr59** » Mon Jun 19, 2006 22:37

amarshall wrote:
P.S. - did you remember to get a new hinge pin while you were at it ? If the old one is seized it probably won't be re-usable.

Good point, one on way with beam.

dpr59 · Post by **dpr59** » Wed Jun 21, 2006 07:20

Wednesday 07:25hrs.

Doorbeam has just been delivered. Postie starts earlier than I do

Thanks Mike

amarshall · Post by **amarshall** » Wed Jun 21, 2006 10:24

dpr59 wrote:Wednesday 07:25hrs.

Doorbeam has just been delivered. Postie starts earlier than I do

Wednesday 08:30 - postie delivers new coil for Wesfield + headlamp pod bobbins for Excel.

Sun is shining - BUT I HAVE TO WRITE A FUNDING BID! - not allowed out to play until it's done

dpr59 · Post by **dpr59** » Sat Jun 24, 2006 12:48

Well I've started.

First two pics are what I found in the door, or not found, however you view the state of the existing beam.

Then removed.

And the new beam in place.

Guess I'll be using the Pug for work next week.

Hopefully I'll get it done before my holidays, next weekend!!!!!

amarshall · Post by **amarshall** » Sat Jun 24, 2006 13:24

Dave has that beam been galvanised, did you paint it, or did Mike supply it ready-painted ?

Mine needed hammeriting and waxoyling before I was confident to get them installed.

Steve C · Post by **Steve C** » Sat Jun 24, 2006 13:36

How bad was the old one? It looks like surface rust from the picture ... is there a bad spot?

dpr59 · Post by **dpr59** » Sat Jun 24, 2006 15:47

Door beam now painted.

Not galvanised, he's still awaiting delivery, I've painted with hammerite.

dpr59 · Post by **dpr59** » Sat Jun 24, 2006 15:50

Steve C wrote:How bad was the old one? It looks like surface rust from the picture ... is there a bad spot?

Real bad, at the hinge there is a split arounr the box section allowing the door to flex laterally when open.

Got door off without much trouble. However when I tried to back it into the garage it won't start.

I'm guessing the immobiliser is sensing a problem with the passanger door and not disarming.

amarshall · Post by **amarshall** » Sat Jun 24, 2006 18:52

dpr59 wrote:Door beam now painted.

Not galvanised, he's still awaiting delivery, I've painted with hammerite.

I strongly recommend dumping a full can of Waxoyl into the innards of the beam - the bad news is that it's easier to hit the hinge end with the beam held vertically....

dpr59 · Post by **dpr59** » Sun Jun 25, 2006 07:38

Got the doorbeam out without having to remove the glass or frame.

Fron info provide on the forum it can be problematic getting the frame off without it needing some welding afterwards,

You can also now see the state the beam is in,

Steve C · Post by **Steve C** » Sun Jun 25, 2006 09:44

That doesn't look so nice, that's another task added to the job list! Why do these lists only get longer?