repairing bulkhead in situ

Hiya

I've just got the 110 MOT'd and I'm struggling to stay enthusiastic about it. Its on a galvanised chassis, but the bulkhead is starting to rot quite badly. Its looking like about £5k for the shop to do the replacement, so wondering if there's anything a bit more affordable. Anyone had theirs just welded in place? I've got a hole on the outside next to the windscreen, and theres another hole above the pedals in the driver's footwell.
I see a few folks have gone with a DIY on the bulkhead replacement, but I think I'm going to struggle with that - the only space I have is a shared parking area with no cover.

Thanks!

I knwomitnis not quite the seem but I replaced the bulkhead on my series 3 over an Easter bank holiday weekend. Started on the Thursday night and finished on the Saturday evening (long days). Some can be done one your own diy relatively quickly. But this time of year you will be fighting the weather. I defender dash is a little more involved but not hugely.

If you already have a glav chassis a gave bulkhead would be a logical choice and give new lease of life to the vehicle rather than being disheartened.

From the parts you have described if that is the only issue they do not sound like huge areas you should be able to weld in situ. The footwells can be replaced without removing the bulkhead. Throw up some pics so people can really get an idea of how bad it is.

captainmish said:

Hiya

I've just got the 110 MOT'd and I'm struggling to stay enthusiastic about it. Its on a galvanised chassis, but the bulkhead is starting to rot quite badly. Its looking like about £5k for the shop to do the replacement, so wondering if there's anything a bit more affordable. Anyone had theirs just welded in place? I've got a hole on the outside next to the windscreen, and theres another hole above the pedals in the driver's footwell.
I see a few folks have gone with a DIY on the bulkhead replacement, but I think I'm going to struggle with that - the only space I have is a shared parking area with no cover.

Thanks!

Click to expand...

If it helps,

I was where you are 4 years ago and I welded it up and literally cut out all the rot and rebuilt many elements by the windscreen. I put new floor pans in etc had the roof pushed up and doors off..... I am literally in the last 3-4 days resound to the fact I will have to take the whole bulkhead out and replace. You just cant get in to do it fully and even the bits I fixed up and cut out the rot are starting to re-rot from the old rot points.

I know nothing on yours but I suspect the bottom feet of the bulkhead where it attaches to the outrigger will be on the way out and worth checking as well.

If you plan on keeping forever do it properly, if you need to buy a few years have a go. Just going into Oct/Nov is probably not the best of times to do either outside.

Mine really was knackered though and as the outriggers weren't welded on in the right place, I am going to swap for a galvanised bulkhead I have had in the garage for 10 years and fix them at the same time.