Doorbeams

[dpr59]

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

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam01.jpg

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam02.jpg


Then removed.


http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam03.jpg


And the new beam in place.

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam04.jpg

[dpr59]

Door beam now painted.

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

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam05.jpg

[dpr59]

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,

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam07.jpg

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam06.jpg

[dpr59]

This is the bottom edge of the doorbeam now removed from door.

I had to remove the window frame as rear edge of beam wouldn't pass the front frame, not enough space.

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam08.jpg

That's one hell of a drainage channel.

Total strip down time, 4 hours.

After removing all the inspection panels on door.

1. Disconnected all electrics in door.
2. Removed central locking actuator
3. Removed door from car feeding wiring through door as it was removed (this part a two man job).
4. Removed interior and exterior handles
5. Removed window lift motor, used battery charger to move lift mechanism to get to 4th bolt.
6. Removed window frame. Had to drill three rusted screws that go into each frame upright from the outside. Under window seals.
7. Withdraw the beam

If you see a piece of duck tape, there's generally a bolt behind it. Several holding the door to the beam in quite unobtrusive places. If something does move freely look for another bolt or two.

[dpr59]

Assembly.

Part 1

1. Attach locking mechanism to bare doorbeam
2. Align door beam (adjustment on bottom hinge 17mm spanners)
Then remove locking mechanism again.
3. Attach stop plate on inner front doorbeam
4. Slide door body onto beam.
5. Two bolts front and two rear fasten door to beam (all 10mm). Firmly but not tightly screwed up bolts. Then alligned door with car body ensuring top edge level and side curvature matched. Then nipped up all four bolts.

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam10.jpg

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam09.jpg

[dpr59]

Window now in place.

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam11.jpg

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam12.jpg

http://i7.photobucket.com/albums/y280/dpr59/Excel_Doorbeam13.jpg

Just the lift motor and trims left.

So far total time about 8 hours.

One point to note.

There are four bolts in the door lock.
They are not all equal length.

This is because the shorter bolts needs to be in the upper right slot.
The longer bolts interfere with the rear seating of the window frame lower bolt.

Top right, short bolt :!: