Shane512 · May 7, 2018

Hello all,

I’ve decided to go ahead with a chassis swap on my vehicle and have a chassis on order, while I’m waiting for that I’ve done some thinking and want to swap the bulkhead at the same time.

The way I’ve planned to do this is to strip the front end off up to the bulkhead, remove the body off of the chassis onto scaffold bars and axle stands to raise the body high enough to wheel the old chassis, running gear out in one go.

My main question is regarding the structural integrity when the body is not connected to the chassis, if I’m replacing the bulkhead and remove it while the chassis is also removed, does this pose a structural integrity issue? If so, does anyone have any experience of how to maintain structural integrity or is it worth swapping the chassis first and then removing the bulkhead afterwards?

Thanks in advance for any help and advice.

Turboman · May 7, 2018

Shane512 said:
Hello all,

I’ve decided to go ahead with a chassis swap on my vehicle and have a chassis on order, while I’m waiting for that I’ve done some thinking and want to swap the bulkhead at the same time.

The way I’ve planned to do this is to strip the front end off up to the bulkhead, remove the body off of the chassis onto scaffold bars and axle stands to raise the body high enough to wheel the old chassis, running gear out in one go.

My main question is regarding the structural integrity when the body is not connected to the chassis, if I’m replacing the bulkhead and remove it while the chassis is also removed, does this pose a structural integrity issue? If so, does anyone have any experience of how to maintain structural integrity or is it worth swapping the chassis first and then removing the bulkhead afterwards?

Thanks in advance for any help and advice.

Much easier to just take the tub off, and carry it away, followed by the seat box, wings, etc.
Any of the body components are hand portable by two people, most by one person.

Shane512 · May 7, 2018

Turboman said:
Much easier to just take the tub off, and carry it away, followed by the seat box, wings, etc.
Any of the body components are hand portable by two people, most by one person.

I had thought of this but heard horror stories of alignment when trying to fit it all together, what are your thoughts on this?

Turboman · May 7, 2018

Shane512 said:
I had thought of this but heard horror stories of alignment when trying to fit it all together, what are your thoughts on this?

Shouldn't be too bad if you go about it the right way. Plenty of info on the forum about it.
I seem to remember you are supposed to attach the tub to the new chassis, and align the bulkhead from that.

It isn't like a monocoque car, the body simply doesn't have any integrity when it is off the chassis and bulkhead.

Shane512 · May 7, 2018

Turboman said:
Shouldn't be too bad if you go about it the right way. Plenty of info on the forum about it.
I seem to remember you are supposed to attach the tub to the new chassis, and align the bulkhead from that.

It isn't like a monocoque car, the body simply doesn't have any integrity when it is off the chassis and bulkhead.

Thanks for your advice. I’ll do some research into removing the body this way.

Turboman · May 7, 2018

Shane512 said:
Thanks for your advice. I’ll do some research into removing the body this way.

The main thing I remember from re-chassis is to carefully identify where all the wires, cables, pipes, etc go through, or round, the chassis and bulkhead before removing anything. Pics, and little labels attached to the wires etc. will help.

Gmacz · May 7, 2018

If changing bulkhead as well then lifting it out complete would be a waste.
Just pull it apart bit by bit and nothing structural will go wrong.
Roof first and bulkhead last, either chop wiring at the back or disconnect each wire.
Not an easy job but you will figure it out.
There will be a lot of extra little jobs to do as you put it back together.
Back body back on, bulkhead on and adjust to fit doors then lock it with roof.
Ratchet straps are usefully to pull it into shape if it needs it.

Shane512 · May 7, 2018

Thanks so much for the info. I think I’ve made my mind up to strip completely.

Anyone recommend somebody near Oxfordshire/Wiltshire who can repair and galv my bulkhead?

Shane512 · May 10, 2018

Chassis ordered today from Richards chassis. Should arrive in July. Can anyone recommend a compound to place between the mounting points of the chassis and body to prevent dissimilar metal corrosion? I was looking at a compound called JC5A which we use on aircraft, or skyflex tape made by Gore.

My other question is regarding the bolts that mount the body to the chassis, what coating have you used to prevent dissimilar metal corrosion when using stainless steel bolts?

boguing · May 10, 2018

I don't know if you're near the sea, but all chandlers have Duralac. Being boaty it's reassuringly expensive, but prolly dirt cheap compared to aircraft 'spec'.

Shane512 · May 10, 2018

Good choice, I like the look of that stuff. I’m choosing aircraft spec compounds because it’s what I work with for vehicles going 30,000 feet, plus it’s easier for me to get hold of a rogue tube or three when required!

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