200tdi rebuild

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Had a mate round with a welder this weekend and got new feet welded onto my accident damaged td5 bulkhead and made up a brace for galvanizing so hopefully i'll finish stripping it down, knock out some dents and get a price for blasting and galving on friday. Ill get some piccies up as soon as possible.

While i'm looking into the bulkhead, whats the best way of applying filler to a galvanized part seeing as there is the odd mark left from straightening it out? Also has anyone done a definitive list of bolts required for fixing all the various ancilliaries to a bulkhead?

Thanks,

Albert.
 
Few photos of what I've done on the bulkhead ready for galving and the accident damage which I can't sort out easily

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Hopefully I'll get it blasted on Friday and then have it ready for galving next week [emoji4]
 
Not been able to sort the bulkhead out yet unfortunately but hopefully I'll get round to it next week.

In the mean time I've been playing with my new intercooler and trying to get it to fit in the old rad frame.
e10b96423efdd13cc0b3d3edd67e1ef2.jpg

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As you can see it's not going to fit so my plan is to cut out a chunk of the frame on each side then weld on some round rod for support.
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I'll keep you updated with my progress soon.

On another note, does anyone know where I can get replacement stickers for the top of the rad frame seeing as I'll be blasting and painting it shortly? I know it's kinda sad going to that much detail but I'd rather keep some originality.
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Sticker shop and get some copies made up, then sell the excess ones on ebay, I bet they will sell well.
 
Quick update,

I've sourced a second rad frame which i plan on mounting to the back of the current one to allow the radiator to be sat in a proper frame. Got a few days booked off at the end of the week so ill get my bulkhead sent off for galvanising. While i'm at it ill get a load of parts blasted for painting. Other than that i've only been doing odd bits and making a shopping list for billing :D
 
I've solved the issue with the fouling pipes

https://www.dropbox.com/s/wau7xsio9hsfnh1/IMG_2539.JPG?dl=0
https://www.dropbox.com/s/1v76bq6pm6ccf1c/IMG_2540.JPG?dl=0
https://www.dropbox.com/s/dm83dhhyivd87gz/IMG_2541.JPG?dl=0
https://www.dropbox.com/s/ebmeyy1uhzbsnav/IMG_2542.JPG?dl=0
https://www.dropbox.com/s/y0wyk4vfrsgfhbt/IMG_2544.JPG?dl=0

I also made up a VIN plate and repaired the downpipe (fancied a play with my new welder)

https://www.dropbox.com/s/9wx2lqfqnartrbm/IMG_2546.JPG?dl=0
https://www.dropbox.com/s/gtz1dkdzh7uezs2/IMG_2550.JPG?dl=0
https://www.dropbox.com/s/asye3hi7slovzl3/IMG_2551.JPG?dl=0
https://www.dropbox.com/s/44nd9ozeqnmr0gi/IMG_2552.JPG?dl=0

Once i got hold of the second rad frame (Thanks @vilguy) i modified it and welded it onto the original frame.

https://www.dropbox.com/s/dmgqn5pthq33co7/IMG_2553.JPG?dl=0
https://www.dropbox.com/s/c7554vspu2ileih/IMG_2554.JPG?dl=0
https://www.dropbox.com/s/rqr2z0ryjki2g9r/IMG_2555.JPG?dl=0
https://www.dropbox.com/s/8d0qt2ir0k27q1w/IMG_2556.JPG?dl=0
https://www.dropbox.com/s/36haijb23c69jlh/IMG_2557.JPG?dl=0

And when I was bored for a moment i serviced and painted the handbrake

https://www.dropbox.com/s/2csjawvmh0l2pcr/IMG_2560.JPG?dl=0

In other news i will be picking up the bulkhead tomorrow from the galvanisers and ill be buying some paint for the bodywork. I've gone of the green now seeing as it'll be my daily drive so i'm looking at a nice none metallic gunmetal broken up with gloss black parts.

Also i apologise for all the links, i don't know another way of uploading just yet.

Albert
 
Last edited:
Got the bulkhead and bonnet frame back from the galvers and other than the odd slightly distorted bracket they are looking good. Test fitted the bulkhead only to find the brackets are about 4mm out and the bellhousing fouls on the tunnel but with a bit of tweaking it should all fit. No more pics or posts now until someone lets me know how to get images working properly by phone.

Albert
 
Not posted for a while. Painted the bulkhead now, gone for bonnati grey now. Engine started first turn after bleeding up. Just attacking the wiring now before bolting on anything else. Sourced a decent tub and seatbox. Test fitted all the body work and it all lined up nicely. I have loads of photos but I don't have a way of uploading them. F*****d off photo bucket cos I got endless emails of crap off them even though I set it so I shouldn't. No more pics until an app or some way of uploading direct from my phone is sorted
 
Right time to revive this thread. Made slow progress which is really dragging now. Working 2 jobs really isn't helping. Anyway, here's some photos of the bulkhead how I got it and painted up. I'll keep adding pics as and when
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