C.A.R.

This is a basic tutorial for the removal of the door skin on your Zed. The only reason you would want to do this is to fix rust in the frame of the door, Or to perform rust proofing to the inside of the skin or frame. You might also do this to perform panel beating work. Tools: Mig welder Angle grinder (with wire brush & cutoff disc). Door skin removal tool. Clamps Wooden dolly Hammer Before you begin: Get yourself an old flat blade (wide as possible) screwdriver that you don’t mind ‘butchering’. With Oxy or propane torch heat the end of the screwdriver till its ‘cherry red’. Place 10-15mm of the end of the screwdriver in the vice & bend it around as far as you can. Then hammer the end of the screwdriver around until it’s at 180deg (see pic). While it's still red hot, drop the end of the screwdriver into some used motor oil - this will have the effect of re-tempering/hardening the end. This is now your special door skin removing tool! Step 1: Strip the door down, remove the window frame followed by the glass, runners & locking mechanisms. Use the workshop manual as a guide to help you disassemble the door. Put the door internals out of the way where they won’t be disturbed. Step 2: You should now be left with a bare door. Taking your angle grinder with a wire attached, wire brush the seam around the outside edge of the door where the door is folded over. At this stage you can buff any other rusty patches on the door Change to a 1mm cutting disc & cut the two welds at both ends of the door at the top. This ‘should’ now render the tops of the door free once you’ve finished unpicking the folded seam.

Wow! You bought some hoses!

Umm... Maybe...

Jeeze... And I thought Hunter was weird...

Hot Dog! Looks smooooooooooooooth Dave!

We need funds to start doing that Jeff - & atm we don't have that sort of $$$. We need donations...

If you search for 'Datsun' or '240Z' on Google.com (not com.au) this site is on the first page! That's VERY impressive - it's even above ClassicZcar.com & hybrid! That's why this site has been getting so much traffic. Well done to Gav!

I'd be calling Warren at AllZparts in Sydney for all that stuff...

I assume they are not real British SU's?

So ANOTHER person trying to sell their own crap, eh...? Better explain yourself quick smart, BlueTim.

Sorry Gun - was just trying to share the love mate...

No need to be shy Stew! Please come along & introduce yourself!

I won't be fitting my set for a little while yet. I believe however we'll be fitting the "Toecutter's" one's first... I don't envisage any issues BTW Ben I received my set. I'm quite impressed with the product. Thanks very much for all that!

Where: Jaguar Car Club of Victoria, 23 Rosalie St, Springvale, Vic. 3171 (Just off Springvale Rd)

There's a diference between S1 & S2 2+2 Doors. The Bus is a late S1 I believe Dave...

Only your mind would make that connection Shaun...!

Sand, Rust convert it, then repaint.

While I was waiting for the old man to finish with the angle grinder, I decided to remove the door catch - it turned into a right PITA... The plate behind in the C piller was fairly fooked... I found that there was no thread left in the top hole & there was a seized bolt which I had to drill out. So I decided to remove the plate to fix it properly... Two spot welds drilled out & the plate fell out the bottom (where the sill is open atm where I'm repairing it). So I welded up the holes & redrilled/tapped 6mmx1.0 them - just have to replace the plate now Let me know if I'm boring people...

Welcome to the nut house. Watch out for Pauly...

I'm now onto the last bit of rust that needs repairing - the DS dogleg. I need to fab up a new inner section first, then the outer panel can be welded back into place.

Slowly!

Sul, that's a generic photo - the Zed inserts don't look like that at all. How about we just re-oil the OEM wet inserts - then you can decide on what adjustable inserts to use after that?

Looks like a reasonable turnout...