Puma bulkhead

Johnny.gte · Sep 6, 2017

About to replace my bulkhead on my td5 with a complete tcdi any good tips , going down discovery gearbox route , my bulkhead is mint but fancy going down the cosmetic looks and quieting her with more sound deadning

alexc2701 · Sep 6, 2017

I did disco box too to plus the heater works pretty well. Mines to a 300tdi engine so maybe easier. Gatso did a custom lever housing so he could use the tdci tunnel and levers without cutting seatbox. Think he had a pneumatic hi low lever. I just cut seatbox and made a custom gear tunnel and plan on making a custom centre console/armresty/cubby boxy thing. and using D2 gaitors in it.
Wiring the lights and stuff in is pretty annoying and there's tons of wires in it you won't need from ecu and electronics. I got one with leccy window wiring in so be easier than if you're adding in. Gana use a central locking kit rarther than making the wiring in the tdci bulkhead work cos be easier. If you have a td5 now you might be able to use your system from that if lucky.
Make sure you get the heater air intake vent, you'll have to move your screen wash if it's in the same place as a 300tdi on td5 cos that vent.
If you go for puma bonnet too you need to offset your coolant resevoir again if it's in the same place as a 300tdi. Not had a td5 defender before just a disco
Make sure you have a tdi disco box you can't use a td5 disco box cos no speedo running gear I think.
I wish I'd made myself a new loom rarther than keeping the old ****ed about with one if yours has been messed with abit I recommend saving hassle and going new
You need to either swap the drum and handbreak or mod the disco one for def cable which you probably already know
Clocks I'm just using a peice of carbon fibre or ally with td5 clocks mounted on. Someone on here made a td5 set fit into the tdci surround though that looked awesome but like 150 quid for the tdci clocks to then chop up

Not sure if you needed new floor panels or not I did alot more than just the bulkhead so could have been from swapping a diff bit.
Don't let the heater control cables get rusty or bent it's really easy to do and they're 15 quid each and bastard to find
Don't forget to swap barrel or get new set for that and doors if want same

Mulcaster1 · Sep 6, 2017

Johnny.gte said:
About to replace my bulkhead on my td5 with a complete tcdi any good tips , going down discovery gearbox route , my bulkhead is mint but fancy going down the cosmetic looks and quieting her with more sound deadning

Use some dynamat if you get a chance Johnny.gte. My puma is covered with the stuff but the other day I gave our local LR dealer a lift in it. He couldn't believe the result!! Pity you don't live near Cumbria as I have some left pal

Johnny.gte · Sep 7, 2017

alexc2701 said:
I did disco box too to plus the heater works pretty well. Mines to a 300tdi engine so maybe easier. Gatso did a custom lever housing so he could use the tdci tunnel and levers without cutting seatbox. Think he had a pneumatic hi low lever. I just cut seatbox and made a custom gear tunnel and plan on making a custom centre console/armresty/cubby boxy thing. and using D2 gaitors in it.
Wiring the lights and stuff in is pretty annoying and there's tons of wires in it you won't need from ecu and electronics. I got one with leccy window wiring in so be easier than if you're adding in. Gana use a central locking kit rarther than making the wiring in the tdci bulkhead work cos be easier. If you have a td5 now you might be able to use your system from that if lucky.
Make sure you get the heater air intake vent, you'll have to move your screen wash if it's in the same place as a 300tdi on td5 cos that vent.
If you go for puma bonnet too you need to offset your coolant resevoir again if it's in the same place as a 300tdi. Not had a td5 defender before just a disco
Make sure you have a tdi disco box you can't use a td5 disco box cos no speedo running gear I think.
I wish I'd made myself a new loom rarther than keeping the old ****ed about with one if yours has been messed with abit I recommend saving hassle and going new
You need to either swap the drum and handbreak or mod the disco one for def cable which you probably already know
Clocks I'm just using a peice of carbon fibre or ally with td5 clocks mounted on. Someone on here made a td5 set fit into the tdci surround though that looked awesome but like 150 quid for the tdci clocks to then chop up
Not sure if you needed new floor panels or not I did alot more than just the bulkhead so could have been from swapping a diff bit.
Don't let the heater control cables get rusty or bent it's really easy to do and they're 15 quid each and bastard to find
Don't forget to swap barrel or get new set for that and doors if want same

I wanted the d3 centre console too but didn't realise that it was custom made lever housing , thought it was fitted to disco box

alexc2701 · Sep 7, 2017

Johnny.gte said:
I wanted the d3 centre console too but didn't realise that it was custom made lever housing , thought it was fitted to disco box

He didn't use d3 one he used the defender tdci one to match bulkhead. You could use a similar custom housing to use the d3 hi low too I suppose.
You can fit a d3 one but the hilow button obv useless. Could always blank off. Think the one I saw his hi low came out infront as D2 box in like a box at front of the console in a d3? It was very tight for room though think he just made a leather gaitor for it.
Personally I think making one out of wood and wrapping it in leather will be better result. More effort but custom fit. Could do it to fit like the expensive conversion companies do. Look awesome. Saw one like

I like the angled ones. Most of those use an auto box conversion looks very similar to D2 gaitors. Won't be hard to make. I'm thinking wooden frame and some sound foam on bottom to level it and take noise out couple of rivnuts to fix in place. Then wrap in leather or the fake stuff. Get armrest where fits nice too. Just unsure whether to do ally or met plate or wood and carpet it for Base. Could also make one out of only metal and weld up I'm undecided

options. Been too busy recently to finish anything off
The d3 console too found it

Johnny.gte · Sep 8, 2017

That's the look I want to go for really , not bothered about cost , got a complete mint TD5 bulkhead to sell and a 70k gearbox that will go towards build bill

alexc2701 · Sep 8, 2017

2nd and 3rd on the top pics I showed is what I want, bet the like cubby console be expensive af though. Never tried leather wrapping but how hard can it be. Prolly try on door cards too cos got couple scratched ones look awesome in leather too. Just need ton of spray glue haha
You should get decent price for your bulkhead and box, you doing a full rebuild while off or galv chassis? Seems logical with how much already be stripping
Can't remember prices on d3 consoles when I looked but wasn't cheap

Puma bulkhead

Johnny.gte

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alexc2701

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Mulcaster1

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Johnny.gte

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alexc2701

Active Member

Johnny.gte

New Member

alexc2701

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