Honest opinions required on Bulkhead repair...

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joe27979 said:
indeed, honesty pays as they say!
Thanks for the advice amigo.......i'll prob cut a piece out of inside skin and look insisde to assess damage. Will keep ye all posted!
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Aye nae wurries;)
Get yersel' down tae yer local breakers and see if they've got owt in. Ye never know and if they do it might be a guid yin;):D
 
Well I had another go at removing some bits today, wiring loom unclipped and steering dismantled...poked with a bigger screwdriver.. SSHHIITTT

holes in panel behind steering and holes along front skin of vent flap...

Looks more and more like a bulkhead out job.


Whats next to getting the bulkhead out, bonnet and wings off?
 

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I had similar questions about my 200tdi, when i bought it- although mine was worse than that. In the end i found a garage that supplied a very solid replacement from a 300tdi. They supplied it and warranted it for £300, and fitted it for another £300, as well as supplying me with a G4 courtesy car. The bulkhead also came with loads of freebies- immaculate dash, new wiper motors (mine were knackered) etc. I was bracing myself for a bill well over £1000, and for the vehicle to be out of use for at least a couple of weeks. In the end i had it back in a matter of days. I suppose this just shows that replacements needn't cost the earth, and if you've got somewhere to do the work yourself (i don't, unfortunately), all the better.
Good luck.
 
director_steve said:
I had similar questions about my 200tdi, when i bought it- although mine was worse than that. In the end i found a garage that supplied a very solid replacement from a 300tdi. They supplied it and warranted it for £300, and fitted it for another £300, as well as supplying me with a G4 courtesy car. The bulkhead also came with loads of freebies- immaculate dash, new wiper motors (mine were knackered) etc. I was bracing myself for a bill well over £1000, and for the vehicle to be out of use for at least a couple of weeks. In the end i had it back in a matter of days. I suppose this just shows that replacements needn't cost the earth, and if you've got somewhere to do the work yourself (i don't, unfortunately), all the better.
Good luck.
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Thanks Steve, as you say it can be done at a good price but it is certainly a case of "who you know"! What garage did you use if you dont mind me asking?
 
ok, progress so far.
Got home and sprayed the front fencing for the missses as well as put her up some trellis...bless, now into the garage!

Id started taking engine bits off the bulkhead yesterday, lots of tight places to get too in the wing so lots of cut knuckles getting this bad boy off.

A couple of pics of near side wing off, bulkhead looks in really good shape here, no signs of rust at all...spoke to a chap the other day and he reckons mine looks like it has sweated from the inside out, rather than rusting outwards into the cavity..doh!

While taking wing off I knocked brake pip and now there is frikkin brake fluid weeping out of the fitting, and the pipe is loose and wiggly - another repair!
while im here with the wing off, would you guys recommend doing anything else other than the usual cleaning up?

thanks - i'll keep you posted on off side wing im hoping to get off tomorrow.
 

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Me again,
Not much response to my last porting but i'll keep updating anyway for future site visitors doing a search for "bulkhead" related items :eek:)

Got the drivers wing off today, brake pedal removed (thanks for the tutorial link Buster)...just clutch master cylcinder, steering column and wiring loom to go now!....any tips on removing the loom?

Below are some updated pics and following on from this post is a video of the bulkhead removal so far.

hope it is of some interest to someone other than me ;o) lol
 

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joe27979 said:
Me again,
Not much response to my last porting but i'll keep updating anyway for future site visitors doing a search for "bulkhead" related items :eek:)

Got the drivers wing off today, brake pedal removed (thanks for the tutorial link Buster)...just clutch master cylcinder, steering column and wiring loom to go now!....any tips on removing the loom?

Below are some updated pics and following on from this post is a video of the bulkhead removal so far.

hope it is of some interest to someone other than me ;o) lol
Click to expand...

When ye come tae remove the loom, have some maskin' tape and a guid pen that doesn't rub off, for every wire / plug / connector that ye take off stick a piece o' maskin' tape on each side and write the same number on each piece.... makes life so much easier when ye come to refit it (that should've included yer dash clocks);):D
 
Oh, and incase ye're wonderin' about how to get the wee black plastic cover off that's in the engine side where yer wires come out the bulkhead..... they're like the plastic rivet things that hold yer wheel arches on (a wee pin in the centre that needs pokin' out);):D
 
video link as promised:

[nomedia="http://www.youtube.com/watch?v=MlynDftZVHY"]YouTube- Defender bulkhead removal[/nomedia]
 
I can always rely on the Buster for a friendly reply and advice.

much appreciated amigo, cover removed ok...I though christ how am i gonna get the wires out the back of the fuse bar!! But now I see I can unplug all the connectors in the engine bay and pull them through to the inside of the car.

Not long before its removed now and for me to decide if im gonna tackle the repair myself.
 
joe27979 said:
I can always rely on the Buster for a friendly reply and advice.

much appreciated amigo, cover removed ok...I though christ how am i gonna get the wires out the back of the fuse bar!! But now I see I can unplug all the connectors in the engine bay and pull them through to the inside of the car.

Not long before its removed now and for me to decide if im gonna tackle the repair myself.
Click to expand...

Ye're welcome joe;)
Once the wiring is out, there's not a lot else to make the bulkhead come out. The steering collumn can stay in place as long as ye've removed the collapsible shaft ..
steeringcolumn001.jpg


steeringcolumn003.jpg


Then it's just a case of removin' the two long bolts that fit through the bulkhead and onto the sills...

bulkheadmisc024.jpg


bulkheadmisc025.jpg


and then lifting it out...

bulkheadoutandin001.jpg


bulkheadoutandin002.jpg


bulkheadoutandin003.jpg


bulkheadoutandin004.jpg


bulkheadoutandin005.jpg


;):D
 
Sweet cheers buster-I thought I took a lot of pics but seems you enjoy cataloguing your work just as much! :0)
It does help us novices tremendously so keep it up!
Just wish I had a nice shiny bulkhead like you did to swap it with now!
 
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