Series 3 Bulkhead Rebuild

BIOSBILL · Oct 2, 2007

Hi,

My series 3, looks great outside and underneath, but both the footwells are starting to look a bit iffy, you cant see through them as they're plated, but the splash guard has come loose, and they look a bit tatty from underneath.

So over the winter planning to strip out the buldhead, brush up on my welding, and weld in some new ones.

Any big problems?
Easiest way?
Does the bulkhead have to come out? (think ive seen it done without)

Im dreading taking out my dash wiring, its brand new, but Ill have to label it all!

Thanks

doobie · Oct 2, 2007

i'm pretty sure you can sort your footwells with the bulkhead still in situ, there's loads of room under them wings, i found a church under mine once!

clivees · Oct 3, 2007

No prob
You can get to most bits without taking off the wings, but it makes for a neater easy-er job if you take the wings off.
Taking the wings off has the added bonus that you can get to some other matinace such as replacing ball-joints and painting chassis etc.

clivees · Oct 3, 2007

Ps
Some general things to watch out for when welding
1. whats behind the bit you want to weld?
2. watch out for the petrol pipe which located close by.
3. watch out when welding the chassis cau it sometimes has wiring running through it.
4. dis-connect the bat if using a electric welder and be careful about welding close to a freshly charged bat as they give off hydrogen/oxygen when charging.
5 never weld on somthing between you and the only exit.

BIOSBILL · Oct 3, 2007

ok, thanks for the help!

do u think it ncessary to take the dash out, to cut out/weld in footwells? I really don't want to tackle the dreaded dash wiring!

thanks

clivees · Oct 3, 2007

Leave it in just be careful about where you weld.
If you have any trim/carpets/soundproofing etc fitted with in 6" of the weld then remove it.
I would have the misses standing by with fire extinguisher just to be on the safe side.

Series 3 Bulkhead Rebuild

BIOSBILL

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doobie

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clivees

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clivees

Well-Known Member

BIOSBILL

New Member

clivees

Well-Known Member

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