Apologies for the first version of this which posted a web link. Not intentional advertising and placed to highlight some similar work I am considering. This was in regard to fabricating a replacement Defender bulkhead. This was suggested to me by a Jeep owner who does a lot of off-roading here on Vancouver Island. Him and his pals have an alum fabricator here in BC who make quick-and-easy replacement panels. The same crowd have moved into replacement bodies, bulkheads/firewalls for 'FJs'.
I asked them if they would consider building replacement Defender bulkheads. They are interested and have plans in place already to explore this.
They asked how much interest is out there to get them underway. Knowing how many old Land Rovers are out there and with the numbers coming across to N America, I sensed there may be a significant demand.
I am interested though, if this has been explored before. I suspect it has but for one reason or another has never got too far. The thoughts of members who have been there, done it would be appreciated.

Would they be manufactured using ali? The bulkheads are steel for a reason, they’re quite important to the structural integrity of the front-end, which the Defender design is lacking anyway.
Galvanised steel is the preferred material for aftermarket bulkheads.

As above, I prefer having at least some steel around me
A galvanised bulkhead reduces the chance of rust and gives a small amount of protection

Looks good, I’m not doubting the quality of their work - it looks to a very high standard, but still won’t be as suitable as steel for its end use.

I think there would be more demand for all alloy defender doors, or even just alloy door frames. There's a sizable market there already, and if they can get close to the cost of steel doors I think it's a winner.

Thanks for the comments and concerns about strength. (I thought the LZ crowd would take rust-free over safety any day!). I am following up with them into the new year about this after they have explored it more themselves. I'll let them know the concerns around strength and safety and see how they respond. Cheers!