Folding Shelf

The rear door of the Discovery is "padded" with plastic-coated cardboard and has 2 compartments that tend to break.

I decided to coat the inside of the door with a 2mm thick aluminum sheet and to install a folding shelf made of 1.5mm thick aluminum.

The dimensions of the rear panel were taken from the original covering, and 50mm were cut from each side of the shelf to allow for the installation of rubber edges to prevent cuts. This rubber contains a metal strip along its length in a U-shape to maintain its tension and shape. The cutting of the panel and the shelf was done using a manual vertical saw (jack-saw) with a special aluminum saw blade (a regular metal saw tends to vibrate during work and produce an uneven cut).

All the screws in the rear panel and hinges were coated with blue Loctite Tite'n for bolts. This adhesive prevents the screws from loosening under vibrations. The screw holes in the panel were drilled first with a 3mm drill bit and then with a 10mm drill bit to a depth of 2mm to create a recess so the screw head would not protrude from the panel itself. The screws used are sheet metal screws.

At both ends of the shelf, a plastic-coated steel cable was attached. The end was made by bending the cable, wrapping it with electrical wire (after removing the insulation), and then using heat-shrinkable rubber. The end was inserted into a cable lock, with the U part of the lock passing through the aluminum panel at two holes and being tightened through it. This method creates a strong cable end that takes up minimal space.

Additionally, a rectangle was cut into the rear panel to house the opening handle. The original handle was removed.

The locking of the shelf is done using a locking hook used for trailer doors. A fine thread was created on the back part of the hook, and a nut was adjusted to it. Fine threads withstand tightening pressure better and help secure the shelf. The hole for the lock hook in the shelf was made using a hole saw.

Additionally, holes were made in the rear door to create space for the hinge screws and the cable locks in the panel.