Hello,

This has been a long time coming but I'm finally starting to restore my 1992 200tdi, which has seen better days (or at least certain parts of it have...)

I need to repair the bulkhead, I've got a TD5 bulkhead that I bought a few years ago, however now that I live around the corner from a galvanisers I'm considering repairing the current one (depending how bad it is when I get it off) and getting it galvanised. We'll see.

Other bits on the list are some work needs doing on the chassis, both bulkhead outriggers plus there's some other crunchy bits. I'm toying with getting a galvanised chassis, as would mean no need to worry about it again, plus I'm potentially emigrating abroad next year, which would mean getting a galvanised chassis at a later date would be significantly more expensive.

Doors need their frames repairing, which is what I've started with today and what I have a question about.

I've cut off the bottom bits where they are corroded away, and have cut just above the where the bottom hinge attaches. I saw there were some tubes through, and decided I could get new tubes, however once I've got it off I notice that there's more support between the frame and the skin - what should I do about this on my repair piece? I've had a bit of a search and can't see any other people asking.....not sure if that means noone else has bothered, or maybe nnoone else cut that far up

I'll get some more photos up later, however to start with:



Old vs new :


Removing rusty metal

Make sure you get the stiffener tubes back in where the windscreen hinges bolt through, they are useful.

Pics don't show the area you are asking about on bulkhead?

Not sure what you mean about cutting at the hinge, usual is to bolt on a new pillar and weld it on?

It's the doors I've started with, so where the hinge attaches to the door

This bit:

gse1986 said:

It's the doors I've started with, so where the hinge attaches to the door

This bit:

Click to expand...

Sorry! Thought you meant the door pillar, as posted in the pic. Never tried to repair the door frames myself, sure someone will have, tho!

Any one any ideas?

Been having a think and maybe just add an extra piece where the hinge will go (but behind the skin) and then maybe get some tubing of the right size and weld in?

Cut out some on the other door today, annoyingly caught the skin a bit, however hoping a little bit of filler when it's all back together will make it not noticeable.

Also did a little patching on the new bulkhead, it had some bits that I'd cut out but not patched back, hopefully it's something I can get sorted in the evenings.

Ideally I don't want to take the land rover to pieces for a few weeks, as will be going away at the beginning of July, and so leaving it in pieces wouldn't be ideal.

So my plan is to buy some mild steel tube, cut to size and weld in. Currently having some issues finding anywhere local that sells steel tube, plenty of websites charging £20 postage for £1 worth of tube, anyone know any good hardware/engineers shops in the Southampton area?

There was a fantastic one back home up near Manchester, but not yet managed to find anywhere down here.

Bit of an update.

New galv chassis has arrived, which I'm going to start painting - got the mordant solution already, I still need to buy some chassis black paint - any ideas how much I'll need for the whole chassis?

Got the landy pretty much apart, only bulkhead and rear tub left on - current bulkhead is really knackered, so I'm just going to get the TD5 one modified and then galvanised, I think it's going to be beyond my skill set to repair the 200tdi one.

I'm putting together a shopping list - i've decided to go for floflex bushes - is it worth going for the floflex bump stops? they're an extra £54 from flolfex, but can get bearmach ones for about £5 each.....

I'm definitely watching this thread. I fancy restoring mine back to almost-showroom glory in 5 years or so (or once it badly fails its MOT)

I am surprised at the last owner of mine for fitting a galv chassis, but then not putting in a galv bulkhead setup, seems a bit stupid if you're already disassembling the vehicle so to speak

Well, somewhat disappointing effort on my behalf on keeping this updated. I may perhaps go back and add more photos, but for the time being the important information is.....

IT PASSED!

I did the MOT on Friday and it had a couple of silly things - tightening steering box (I didn't test it, as I'd not touched it, but it seems the nut managed to loosen itself slightly since it last got MOTd, not noticeably, but enough for tester to notice. The others were a split pin, a bolt needing padding out with a washer and then the binding brakes as per my other thread.

Anyway, it was great to drive to and from test centre on Friday, and even better today to have those items checked and get another years MOT