Defender bulkhead

[CAPP0]

Just pondering what to do about a replacement bulkhead for my Defender. I picked one up before Xmas for a good price, although it does need a couple of footwells, but otherwise seems to be pretty sound. The bulkhead in my truck is well past it's prime - it did pass the MOT in Nov but it's not great and I will change it at some point.

It seems that a lot of people get their bulkheads galvanised, but this is not without it's issues, including warping (which you can brace against) and final painting, as the galv surface is not smooth, but of course sanding it off defeats the object.

Just wondering if anyone has any other thoughts/suggestions for how to treat it? I'm thinking to start with stripping everything off it and getting it either blasted or dipped - advantages/disadvantages of either approach?? And then, what to do about treating it for the longer term?

[mikeh501]

only way to be sure is to get a galvanised one. thats the bottom line.

id seriously consider a galv chassis whilst your at it, as a bulkhead change is half the job.

if the bulkhead is knackered, whats the chassis like?

[CAPP0]

The chassis is fairly sound, it's had a couple of plates in its lifetime but currently all solid (I've seen - and painted - a fair amount of it close up after having engine/searbox/seats out).

Main concern about galv is the warping and the subsequent painting, also the huge amount of prep required, not to mention cost and somewhere to get it done.

If I had it blasted, then repaired what it needed, what's the next best option (which doesn't take 6 months to apply!)?

[TimCrighton]

I've got a Galvanised Bulkhead on mine - it was a replacement which was Galvanised when it was rebuilt. I've looked at lots and I've never been comfortable with them when they are painted - the paint finish is always orange peeled. Mine is left unpainted - looks great on Keswick Green. I'll take a snap tomorrow.

[cpas]

I've just replaced my chassis, but got fed up of the project so am going to do my bulkhead as a later project. i think there will be a good couple of weekends' work doing it, so I am going to get the original one as good as I can, then paint is well and fix it with Waxoyl. I'm thinking that it has lasted 20 years already, and was probably not so well protected from new, so if I can get another 10 or 15 years out of it for a few tens of hours of work, then this is fine by me. I'm more concerned about the chassis as this is more structural then the bulhhead (as long as the area around the pedals and steering is OK).

[TJN]

I have a galv bulkhead on my 130. I took a normal one and had it galvanized. Easy process really but my advice is remove the grills from the air vents before galv process as they go solid! Didnt see any warping in mine. costs were £30 shot blasting and £70 for the galving to be done. nice knowing that it wont rot. Paint is fine, you need to acid etch it before painting to allow for a key surface without removing the galv.