I need to take the bl#@dy door off!

[Deep Owl]

Having done 3500+miles visiting Burgos, Valladolid, Salamanca, Avila, Toledo, Cordoba, Seville, Jerez, Cadiz and Granada, I managed to crunch the under-habitation door collar on a protruding kerbstone in a campsite in the middle of France in a rainstorm last weekend!

I had superb service from O’Learys in ordering a new one on Friday afternoon and having it delivered on Saturday morning. I’ve managed to extract the old one in parts, gunk and all, but as you can see from the second photo, I can’t slide the new one in without taking the door off - unless someone has a bright idea on how to do it as is?

Also, what sealants does anyone advise; the sealant outside was solid and firm, that inside where the collar slides in still pliable? Thank you for any help.

 

[suavecarve]

Can you push it up from below. ?

Start with the bottom of the replacement bit on the ground

 

[Gellyneck]

The probability, but guessing, is the under door panel is fitted first and then the side skirts.

Could you cut a "slot" out of the side skirts to allow your new part to slip in and then fill with sealant?

 

[berni109]

Carefully cut the lip off that fits under the door frame and seal with puraflex40.
Or take the door and frame out.

 

[Gellyneck]

Carefully cut the lip off that fits under the door frame and seal with puraflex40.
Or take the door and frame out.

If the original panel had these lips would there be a remaining gap under the door frame to accommodate the new panel?

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[Gromett]

I can't see how you would do that properly without removing the door frame.
If you cut anything away you may be causing issue for the future with leakage.

 

[1967bowesj]

If you dont want to remove the door casing to fit the trim behind why not remove all the trim edge that should go behind the door case. Fill the doir case gaps with sikaflex or other know sealant. Then mout the new piece as normal and fill the joint between door case and body panel, tooling to a nice finish.

Was the original over the other two sections and behind the door casing?

 

[1967bowesj]

I cannot see the trim being behind the door casing, it sits flush with side wall so would cause a change in depth, door would kick out away from side wall?
Can you take a pic of the section to the side of the doir inline with the side trim position

 

[Boldly]

If the new panel fitted behind the door trim then surely there would be a step in the door trim.
I think I would trim it flush and seal it.
Edit beaten to it again.

 

[Brains]

I seem to remember dynamite worked for Michael Caine!

I'd put that side of the van on your ramps so that you can get a good look at the underside before you even start to work out how to do it.

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[Deep Owl]

I can’t push up from below because the two “ears” won’t bend away far enough; or rather, I don’t want to risk snapping it at £199.99 a pop!

As Grommet says, I’m not keen on cutting away which might compromise its integrity. The original was over the metal side panels and under the door frame. There is about a 5mm gap between the metal behind and the doorframe, and I did have to pull out the lips from there. The new one is identical to the broken part.

What Sikaflex would be advised for the door frame and collar, or would I need different ones?

 

[Landy Andy]

I would remove the door frame and fit it properly. At that cost there is no point taking risk, or cutting corners. Take your time, clean everything as you go, and do it correctly.

 

[Boldly]

Could you cut it in half at the bottom and slide each half in from the side. Then rejoin at the bottom with some sort of trim?

 

[1967bowesj]

I would remove the door frame and fit it properly. At that cost there is no point taking risk, or cutting corners. Take your time, clean everything as you go, and do it correctly.

What Landy Andy said, get door and frame out clean everything then put panel in a door over top.

 

[nicholsong]

Have you tried getting Bessacar's opinion?

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[Gellyneck]

Have you tried getting Bessacar's opinion?

My money's on "take it to our closest approved dealer/ service agent"!

 

[Boldly]

If you did it in two halves you might only have to replace one of them the next time.

 

[Gellyneck]

If you did it in two halves you might only have to replace one of them the next time.

Low blow!

 

[Deep Owl]

If you did it in two halves you might only have to replace one of them the next time.

If you’d been there last week ……

Anyway, my wife says it won’t happen again!