bulkhead repairs

[MattW]

20+yr old series 3
unfortunately spent most of its life outdoors :(

The bulkhead is in good condition apart from one side where the rust has made its way through a corner under the wing-mirror bracket (see pic) I've given it a quick blast with a rotary wire brush to clear some of the worst rust.

I'd like to get this series on the road again this next year (I belive it was last on the road in 1992.)

What's the best way to go about fixing this hole in the bulkhead???

thanks
Matt

[Rich_P]

What picture should I see?  :?:  And what headlight bracket on the bulkhead?

[mark.yellow.series.3]

i would replace the bulkhead for an after market one, big job but worth it, youll never have to worry about it again.

[Rich_P]

Hmm, picture now displays...  Anyway, that's just the corner piece.  You can buy replacement door pillars.

Probably just see if you can patch it in the short term.  Just remember to not weld near the aluminium, or the aluminium will melt.

[blackbob]

get a repair pannel

[ian_s]

i'd get a repair panel, if you can weld or know someone who can.

to fix that, i'd say:
door off
wing off
bonnet off
cut out the rusted part, back to good metal
cut the repair part to fit,
weld it in

paint it.

wing on, door on, bonnet on, done

oh, if you cut out the part where the hinge bolts to, put the door back in place before tacking the repair part in place, to get the right location.

[MattW]

thanks guys - had a look on paddocks and I believe the weld on part I need is ~ £12.50. Handily I have a friend with the same problem but on the other side of the cab so maybe I'll buy a pair.

This is just the start of a few things I need to do to her

* the clutch has stopped working, I managed to free it once by way of starting it in gear and violently stomping on the brake and clutch. Not sure wether it would be the master cylinder or the clutch it-self that's stuck now :?

* one of the leafsprings came through the chassis during an offroad session last year. - Think I'm going to have to buy a replacement rear 1/4 chassis.

*It's burning oil

hope it's all worth it
Matt
P.S> I've put this in a new thread also

[Big Rich]

You know its worth it mate. You know where I am if you need a hand. Working on mine this week and next  

P.S. Lorna's Dad is an ex REME welder and metal smith

Rich