Recommend me a bulkhead.
Discussion
Well after 15 years of some fairly heavy use it's inevitable I guess....
Bulkhead has a few ominous holes appearing, notably around the top corners, although they're not show-stoppers yet.
I know the Japanese lot will be over in a bit to point and laugh but at least with it being Meccano it hasn't killed the car. I've decided to replace it outright so it doesn't keep repeating on me, and on the assumption that if the visible bits are bad, the hidden bits are probably worse.
So, where's a good place for Defender Td5 bulkheads these days?
Bulkhead has a few ominous holes appearing, notably around the top corners, although they're not show-stoppers yet.
I know the Japanese lot will be over in a bit to point and laugh but at least with it being Meccano it hasn't killed the car. I've decided to replace it outright so it doesn't keep repeating on me, and on the assumption that if the visible bits are bad, the hidden bits are probably worse.
So, where's a good place for Defender Td5 bulkheads these days?
Stop being a pussy and get yer welder out! 
http://www.ebay.co.uk/itm/Land-Rover-Defender-Seri...
I charge about 200 quid for this job plus panels.
Or alternatively get one of these.
Zoom in and look at the state of some of those welds!
http://www.ebay.co.uk/itm/Land-Rover-Defender-Seri...
I charge about 200 quid for this job plus panels.
Or alternatively get one of these.
Zoom in and look at the state of some of those welds!
Edited by 25NAD90TUL on Thursday 11th September 14:29
I did consider repairing just the crunchy bits, but considering how much I'd still have to strip the car down to do even that, coupled with how ropey the rest of the bulkhead is likely to be (based on the poor condition of the top corners) I figured an outright replacement that's been drowned in Waxoyl and then given more paint than the Forth Bridge is the way forward.
Given the impending demise of the Defender I'm keen to inject more life back in to mine than it had when it left the factory.
Having got most of the dash out now, and the front wings off, although there aren't any other huge holes anywhere it does seem pretty poor in general, so I'm being a bit preventative in terms of getting it done before it does deteriorate to the point where it's letting water in or bits are starting to fall off it.
Given the impending demise of the Defender I'm keen to inject more life back in to mine than it had when it left the factory.
Having got most of the dash out now, and the front wings off, although there aren't any other huge holes anywhere it does seem pretty poor in general, so I'm being a bit preventative in terms of getting it done before it does deteriorate to the point where it's letting water in or bits are starting to fall off it.
IroningMan said:
Is there any reason not to get a galvanised one?
The galvanized bulkhead I showed is available from Landiman at Crediton Devon.They are about 1200 squids, plus shipping.
It is a good option although much, much more hassle than welding the corners, although the corners usually lead to thinning steel in the vent apertures and around the corner into the door pillar.
People think galvanized stuff lasts forever, it doesn't, I've seen many rusty chassis and b/head where the zinc plating has worn off over the years and rust taken hold.
They last a long while though, just not forever.
Crossflow Kid said:
I did consider repairing just the crunchy bits, but considering how much I'd still have to strip the car down to do even that, coupled with how ropey the rest of the bulkhead is likely to be (based on the poor condition of the top corners) I figured an outright replacement that's been drowned in Waxoyl and then given more paint than the Forth Bridge is the way forward.
Given the impending demise of the Defender I'm keen to inject more life back in to mine than it had when it left the factory.
Having got most of the dash out now, and the front wings off, although there aren't any other huge holes anywhere it does seem pretty poor in general, so I'm being a bit preventative in terms of getting it done before it does deteriorate to the point where it's letting water in or bits are starting to fall off it.
Dash out, wings off, all you have to do is undo the screen retainers, unbolt the roof to screen frame bolts and you're ready to weld, might have missed some little detail with a newer TD5 one, but that is the basic jist. Remove any flammables round the weld area, you get the picture.Given the impending demise of the Defender I'm keen to inject more life back in to mine than it had when it left the factory.
Having got most of the dash out now, and the front wings off, although there aren't any other huge holes anywhere it does seem pretty poor in general, so I'm being a bit preventative in terms of getting it done before it does deteriorate to the point where it's letting water in or bits are starting to fall off it.
If welding isn't your forte do the prep and I'm sure someone will cut out and weld the panels in pretty cheap. I would, I'm in Cornwall if you're anywhere local?
Last for years if lagged in Zinc weld-thru primer on rear of panel before welding it in and painted and looked after properly afterwards.
Mine's gone on the inner skin beneath the windscreen for which I haven't seen a repair panel.
That aside, having taken the wings and dash off I can see now the crease along the top off the footwells isn't far behind, nor the uprights where the door straps attach.
Repairing just the corners would be an utterly false economy.
That aside, having taken the wings and dash off I can see now the crease along the top off the footwells isn't far behind, nor the uprights where the door straps attach.
Repairing just the corners would be an utterly false economy.
Edited by anonymous-user on Friday 12th September 07:16
Crossflow Kid said:
Mine's gone on the inner skin beneath the windscreen for which I haven't seen a repair panel.
That aside, having taken the wings and dash off I can see now the crease along the top off the footwells isn't far behind, nor the uprights where the door straps attach.
Repairing just the corners would be an utterly false economy.
Yeah, I know how they corrode, done hundreds of them. Good panel beater like me would make any required panels, even outer doorpillar skin no probs. Get a decent fabricator to have a look at it, sounds to me like about 500 quids' worth of work, plus any panels which I'd make myself all of them. That piece under the screen for example, mostly that is one strip of steel with one lengthways fold. Bulkhead panel is roughly 1mm, thicker than car upper body which is usually fabricated in 0.7mm for ease of shaping. Steel is cheap 50 quid would cover all the steel to make all your repair panels.That aside, having taken the wings and dash off I can see now the crease along the top off the footwells isn't far behind, nor the uprights where the door straps attach.
Repairing just the corners would be an utterly false economy.
Edited by Crossflow Kid on Friday 12th September 07:16
Of course different rates apply to different fabricators, I charge 30 an hour for that kind of work as do a lot of 'us'. I'd take this on for 500 plus 50 for steel, as I suspect a lot would. Be a cracking job too! Shame you're not local.
Can't see it being worse than this, and this is doable.
Ashtree are another supplier, and do different grades (and prices!!) according to what sort of finish you need.
http://www.ashtreelandrover.com/
http://www.ashtreelandrover.com/
Have spoken to Ashtree and am collecting one on Thursday, pre-primed in two-part etch primer.
For various reasons (most of all the time delay), f
king about getting mine reconditioned isn't an option so the plan is to swap the bulkheads in a day (already stripped the old one so it just needs doors and screen off to get out), then get it repaired and sold on on to recoup costs. It's gone right through in three spots, plus there are loads of other places where it's well on it's way and would only need doing again in a few years hence the clean sheet principle of a new one.
I did ask at my local main dealer if they had a Td5 bulkhead in line with the urban myth that there are a few NOS bulkheads knocking about the LR network, incorrectly priced up at a couple of hundred quid.....
"What's a bulkhead?"
I kid thee not.
For various reasons (most of all the time delay), f
king about getting mine reconditioned isn't an option so the plan is to swap the bulkheads in a day (already stripped the old one so it just needs doors and screen off to get out), then get it repaired and sold on on to recoup costs. It's gone right through in three spots, plus there are loads of other places where it's well on it's way and would only need doing again in a few years hence the clean sheet principle of a new one.I did ask at my local main dealer if they had a Td5 bulkhead in line with the urban myth that there are a few NOS bulkheads knocking about the LR network, incorrectly priced up at a couple of hundred quid.....
"What's a bulkhead?"
I kid thee not.
Edited by anonymous-user on Tuesday 16th September 16:40
Edited by anonymous-user on Tuesday 16th September 16:42
If you get a chance to take a few pics and post them up that would be great. I have a "spare" bulkhead outside which, once repaired (thankfully quite minor, floorpans just starting to go) I will be facing having to fit.
There are some good videos on Youtube as well if you want to watch those first.
Still haven't decided how to treat my replacement one, strip it and get is blasted is probably the first port of call so that I know how much worse it is than it looks! I picked it up for £80 so as long as it's not too bad under the paint it will have been a bargain.
There are some good videos on Youtube as well if you want to watch those first.
Still haven't decided how to treat my replacement one, strip it and get is blasted is probably the first port of call so that I know how much worse it is than it looks! I picked it up for £80 so as long as it's not too bad under the paint it will have been a bargain.
CAPP0 said:
I have a "spare" bulkhead outside which, once repaired (thankfully quite minor, floorpans just starting to go) I will be facing having to fit.
It's actually very simple and in terms of stripping it down there's nothing that can't be done by one person with little more than a 10mm and 13mm spanner and socket, and a cross-point screwdriver.It's just daunting at first. Disconnecting everything under the driver's seat to then drag the loom forward in to the enginge bay, then up the bulkdhead and back through in to the car takes a lot of confidence. Likewise with stripping out all the driving controls (and I mean all of them). I think because they're the most immediate interface between driver and car it really does feel like you're killing it when you take all the pedals and steering column out.
) but haven't tackled a bulkhead yet. Just seems a big task, but I shall set about it at some point, probably not til the spring though. cpas said:
Somebody recently told me that you can buy non-galvo'd ones for around £250 but I think they mush have been winding me up.
Possibly not.When the TD5 ended the bulkhead was rejigger for the bigger TDCi engine and vastly different interior.
Unlike previous model variations, where LR could just about bodge the last of the old stock in to the new model (found out my early TD5 actually has a tweaked 300TDi bulkhead for example) the newest model meant the last TD5 stock was completely obsolete.
Urban myth has it that, as a result, quite a few JLR main dealers or approved body shops had TD5 bulkheads kicking around that were got rid off for a few hundred quid.
Just to reassure you, the new bulkhead is in and the doors are refitted so it's at least weatherproof again.
The front end is nicely covered over with a tarpaulin when not being worked.
Reassembly is taking a little longer than dismantling as it needs to be done methodically, ensuring stuff is correctly routed, seated, connected, sealed or whatever, as opposed to the strip-down which is, bascially, a case of pulling it all apart.
It's also pissing down most days at the moment so whereas I was able to devote entire days to it a couple of weeks ago, now I'm lucky if I get an hour a day
The front end is nicely covered over with a tarpaulin when not being worked.
Reassembly is taking a little longer than dismantling as it needs to be done methodically, ensuring stuff is correctly routed, seated, connected, sealed or whatever, as opposed to the strip-down which is, bascially, a case of pulling it all apart.
It's also pissing down most days at the moment so whereas I was able to devote entire days to it a couple of weeks ago, now I'm lucky if I get an hour a day
Edited by anonymous-user on Friday 10th October 01:18
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