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Offline 90Mike

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Defender bulkhead
« on: January 11, 2009, 14:47:30 »
Hi guys i am looking at swapping the disco for a 90 in the near future and have been looking at a few on ebay. There seems to be 2 common corrosion faults rear x member and bulkhead, I am not going to give the disco away but at the same time i dont mind a bit of work has any one replaced these themselves? and what kind of job is it or anyone got any photos of there rebuild  :)
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Offline L90OOK

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Re: Defender bulkhead
« Reply #1 on: January 11, 2009, 15:17:50 »
Replacing a bulkhead requires a major strip down & rebuild.  However the bulkheads are repairable in situ, as long as they aren't too badly corroded.
The X member is a fairly simple job to replace & easily done in a long day by competant welder.
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Offline MudRat

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Re: Defender bulkhead
« Reply #2 on: January 11, 2009, 18:54:40 »
bulkhead to replace properly is approx 4 day s work and thats if you know what u are doing, repair, all panels can be bought.
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Offline forestrynick

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Re: Defender bulkhead
« Reply #3 on: January 11, 2009, 19:16:02 »
My 90 is going on the bulkhead corner. How successful is an in situ repair? I've seen those corner panels at shows but always thought they were a bit of a bodge!

Don't care too much as when i have the time/money i'll do a ground up rebuild.

Nick
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Offline MudRat

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Re: Defender bulkhead
« Reply #4 on: January 12, 2009, 13:32:26 »
did the top corners and pillars on mine, top corner is easy, undo windscreen bolts, wedge the screen out of the way and work away, if you are luck the dash can stay in place. Pillars need the doors off, the replace the captive nuts (not worth reusing them) mine looks tidy.
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Offline Defender

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Re: Defender bulkhead
« Reply #5 on: January 12, 2009, 20:07:40 »
Quote from: Disco Mike on January 11, 2009, 14:47:30
anyone got any photos of there rebuild  :)
Have a look at my step by step description of how to make a TD5 bulkhead fit a Tdi in THIS POST
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Offline spy

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Re: Defender bulkhead
« Reply #6 on: January 16, 2009, 01:25:03 »
I did mine in situ.  Its not perfect but much better than it was and will do a good few years now I think!  You may as well try, you have nothing to lose but a few quid on repair bits after all! 

Some pics from mine...







Go on, just do it.. 
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Offline L90OOK

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Re: Defender bulkhead
« Reply #7 on: January 16, 2009, 08:40:03 »
Nice job  :clap:
Did you buy the complete upright  :-k
I am just having my replacement bulkhead galvanised  :afro:
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Offline 90Mike

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Re: Defender bulkhead
« Reply #8 on: January 17, 2009, 23:43:16 »
A big thanks for all your replies and for the great photo's  ;) at least i know that a repaired bulkhead can be made to look just as good as a factory item with a little time, i think this will be the way forward when i find the right motor  :D
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Offline spy

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Re: Defender bulkhead
« Reply #9 on: January 22, 2009, 23:54:07 »
Its been a while since i did mine but I think I bought http://www.paddockspares.com/pp/DEFENDER/Chassis/Front_door_pillar_-_LH.html 

I have no doubt I will have to replace the bulkhead eventualy but I reckon it will take a few more big patches over a few more years yet! :D

Cheers,

Mike

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Offline solihull-mick

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Re: Defender bulkhead
« Reply #10 on: January 25, 2009, 11:00:48 »
Quote from: MudRat on January 11, 2009, 18:54:40
bulkhead to replace properly is approx 4 day s work and thats if you know what u are doing, repair, all panels can be bought.


4 Days? does that include a chassis swap and an engine rebuild! lol
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