Rear door panels

[YIPPE]

I removed both rear door panels today to template them up for some ply inserts to continue my timber theme setup. My plan is to add a large table and pocket insert (like factory) to the large door. And actually the same with the little door. Table big enough for jet boiler and pocket for more storage.
I noted the overlapping seal on the plastic panels. And due to that seal I can see why panels are so wavy it doesn't compress enough between screws.
I also noted that where the panels mount they aren't all the same depth/flat. So the plastic panels are curved. More noticeable on the smaller door. To overcome this I plan to use a 6mm ply for more flex. But may try and warp it first to keep pressure off the fixings.
I'm not entirely sure if aftermarket panel replacements are accounting for this.
On the large door it's at the 45 straight near catch latch that it changes.

 

[DaBull]

I removed both rear door panels today to template them up for some ply inserts to continue my timber theme setup. My plan is to add a large table and pocket insert (like factory) to the large door. And actually the same with the little door. Table big enough for jet boiler and pocket for more storage.
I noted the overlapping seal on the plastic panels. And due to that seal I can see why panels are so wavy it doesn't compress enough between screws.
I also noted that where the panels mount they aren't all the same depth/flat. So the plastic panels are curved. More noticeable on the smaller door. To overcome this I plan to use a 6mm ply for more flex. But may try and warp it first to keep pressure off the fixings.
I'm not entirely sure if aftermarket panel replacements are accounting for this.
On the large door it's at the 45 straight near catch latch that it changes.

Hi Yippe, Are you planning on replacing the panels with 6mm wood or simply do an overlay on top of the plastic panels?
DaBull

 

[Defenderlover]

Hi guys, I`m always rely impressed when I see the excellent quality of the Grenadier, even behind the panels. I am repairing my cars myself since over 50 years.It`s my hobby. At the moment I have 5 cars( one of it my beloved Defender MY 2015). I know how it looks behind the panels. I have never had so much quality in a car! I am sure, I will buy one. But not at the moment. Because every completely new car needs 2-3 years to overcome it`s birth flaws!
This car is overweight( 2.8 tons, my Defender weights 2048kg with my camping gear in it, mattress, boxes and fridge). So many people add more weight to it. Why? I will buy the utility 2-seater. Put a mattress 135x185 on a board in it, under the board 4 20x40x60 boxes for stowing, 2 ca. 100 Ah lithium iron batteries and a 2kw air heater from Autoterm under the metal ground plate( there is enough space, if you rearrange all the stuff there and use all the space up to the seats). I just have to find a place for a small compressor fridge, maybe I put it partly on the mattress.
Then I will look for a longer and not so heavy roof rack and maybe a grip at the A-column to enter the car on the drivers side. This will keep the weight much lower.
Yippe thank you very much for the pictures and your ideas! If I were you, I would do as less as possible. The plastic of the panels is the best quality I have ever seen in a car!
Have fun with your car!

 

[YIPPE]

Hi Yippe, Are you planning on replacing the panels with 6mm wood or simply do an overlay on top of the plastic panels?
DaBull

Looking to replace completely. However easier if I just make tables and forget the pockets. Make brackets for tables that are fixed to panel mounting bolts, uses spacers and longer bolts if required, Just like the ineos table I guess. However that table is too thick for me to mount. And just do ply tables to match my theme.
Don't know till you try I guess.

 

[jesmor3]

that small door spot is easily big enough to make it worth making a new panel that is flat up top but goes internal in the bottom half. even just some air tools or something would be great.

 

[YIPPE]

that small door spot is easily big enough to make it worth making a new panel that is flat up top but goes internal in the bottom half. even just some air tools or something would be great.

I saw Black sheep have done a new panel and it holds the jack for the small door