Fitting bulkhead

[V8MoneyPit]

I've modified a TD5 bulkhead to fit an earlier 90 with an LT77 gearbox. When I took the old bulkhead off, it had shims on one of the big bolts and one of the brackets under the sloped floor, but only 2mm or so.

When I've loosly fitted the new bulkhead, there are huge gaps between the brackets and floor. The bracket is adjusted as far back as it will go. Is there a difference here on the TD5 bulkhead. It doesn't look like it as far as I can see.

I've measured the chassis as best I can (new Richards item) and it seems OK.

[Defender]

When I've loosly fitted the new bulkhead, there are huge gaps between the brackets and floor.

I had the opposite. I had to remove some of the shims to get my TD5 bulkhead to fit.
Sounds like typical Land Rover build tolerances.  :lol:
One option would be to elongate the holes in the bracket so you can move it further back.

[V8MoneyPit]

When I've loosly fitted the new bulkhead, there are huge gaps between the brackets and floor.

I had the opposite. I had to remove some of the shims to get my TD5 bulkhead to fit.
Sounds like typical Land Rover build tolerances.  :lol:
One option would be to elongate the holes in the bracket so you can move it further back.

And up!! We are looking at more than half an inch on the drivers side  :shock:

As an aside....
What is the best way to align the bulkhead? Presumably, it can only be done when the other panels in place?

[tack43]

I recall reading somewhere to work from the back forwards, however, the bulkhead usually is the first bit fitted on all the rebuilds I've seen.

[V8MoneyPit]

I recall reading somewhere to work from the back forwards, however, the bulkhead usually is the first bit fitted on all the rebuilds I've seen.

I suspect that is basically right. I'll leave the bulkhead loose until the rear tub and sills are fitted. Then the doors can be used to set the vertical angle of the bulkhead.

[Defender]

What is the best way to align the bulkhead? Presumably, it can only be done when the other panels in place?

I fitted the bulkhead, windscreen etc all loose & only bolted it up tight when I was sure it all lined up.
I didn't fit the wings or doors at this stage, but it looks like I was lucky as it all seemed to line up pretty well.
One problem I did have was that the top edge of the new bulkhead sat about 3/4inch lower on the drivers side (typical Land Rover build tolerances again  :lol:) & when I tried to fit the windscreen to the roof & bulkhead I had to ratchet strap the roof down HARD on the drivers side to get it to bolt up tight. There was still a significant gap, so I used copious ammounts of Sikaflex.  :lol: