Bulkhead post and feet

wickford90 · Jun 28, 2015

I have got to the stage of rebuild where the S2 bulkhead needs work, I have got it off and sandblasted and it's not to bad, but while its off I want to replace the posts and feet and footwell. Is there an exploded diagram of the bulkhead so I can see how it's put together, then I will have a better idea of where to cut before replacing bits and info greatly appreciated. I will got some pics of it tomorrow.

Brown · Jun 28, 2015

Partly that depends on the shape of the replacement bits, I would have thought. All those repair sections that people buy from YRM or similar Bulkhead Right Hand Drive - YRM Metal Solutions. Cut out what you need to accommodate the new bits. I'd also expect that you'd want to make yourself a jig to ensure that all the bolt holes and so on end up in the right place once you've finished!

wickford90 · Jun 28, 2015

Brown said:
Partly that depends on the shape of the replacement bits, I would have thought. All those repair sections that people buy from YRM or similar Bulkhead Right Hand Drive - YRM Metal Solutions. Cut out what you need to accommodate the new bits. I'd also expect that you'd want to make yourself a jig to ensure that all the bolt holes and so on end up in the right place once you've finished!

The small repair sections are straight forward as is the footwell, it's the posts and feet I have concerns with I need to know how they fit so I know where is safe to cut out. I have thought about a jig and pretty much built it in my head, as I'm rebuilding on a galve chassis so I will weld supports on to my existing chassis.

Brown · Jun 29, 2015

Oh good - the jig issue is in hand. Re: the replacement of rusty bits - I'd have still thought that what you cut out will partly depend on the size and shape of replacement bits. Too much and there'll be some award gaps to fill, too little and there'll be overlap. That is, assuming you're intending to use pre-prepared replacement parts. I presumed you'd be using something similar to the lower door pillar and lower door pillar feet on the YRM website. In which case they define what you need to cut out.

Starting about here http://www.landyzone.co.uk/lz/f7/my-new-old-defender-248534-16.html there is some stuff about LZ member PaulD doing something similar

wickford90 · Jun 29, 2015

Brown said:
Oh good - the jig issue is in hand. Re: the replacement of rusty bits - I'd have still thought that what you cut out will partly depend on the size and shape of replacement bits. Too much and there'll be some award gaps to fill, too little and there'll be overlap. That is, assuming you're intending to use pre-prepared replacement parts. I presumed you'd be using something similar to the lower door pillar and lower door pillar feet on the YRM website. In which case they define what you need to cut out.

Starting about here http://www.landyzone.co.uk/lz/f7/my-new-old-defender-248534-16.html there is some stuff about LZ member PaulD doing something similar

Was thinking of getting the full length post and feet, that's why I'm not sure where to cut the old one out.

Brown · Jun 29, 2015

Well, if I were you I'd wait 'til they arrive and then let that define what you cut off.

mistericeman · Jun 29, 2015

I'd go for "Unstitching" rather than just carte blanche chopping out ....the bulkhead IS very complex in it's construction ....

Measure measure measure Brace brace brace

AND be prepared for any rust to be worse than the bit's you can see

wickford90 · Jun 29, 2015

mistericeman said:
I'd go for "Unstitching" rather than just carte blanche chopping out ....the bulkhead IS very complex in it's construction ....

Measure measure measure Brace brace brace

AND be prepared for any rust to be worse than the bit's you can see

Thanks the top part is what I'm not sure about. If I do decide to do my self I will bolt the bulkhead back on to the chassis and then weld braces from bulkhead to chassis to keep it all straight, as I'm rebuilding on a new galve chassis not to worried about the old one. I have had it shot blasted so I can see the extent of the rot fortunately it's not that bad.

Bulkhead post and feet

wickford90

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