Hi, I'm looking for a guide as to what I can expect to pay a garage to replace my bulkhead and possibly chassis on a 1992 Defender 90? I'm taking it to a local garage on Wednesday, the mechanic (who was recommended on here) is going to put it on the lift to check the chassis and recommends that if required, I consider getting both done at the same time. I'm looking at a galvanised chassis which I believe would cost around £1200-£1500 and about £1000 for a bulkhead. Any ideas based on your recent experiences of what the labour charge is likely to be? And also, any advice on other things to consider getting done at the same time, money obviously dependent! Thanks in advance.
Jonnygearbox
Active Member
Foleys charge round 9k mark all in for it all
Stulios
New Member
Spend £300 on an old fiesta with 6 months tax so you got something to ride round in, then do it yourself!
In terms of what else to replace - it really depends on what else needs replacing. Best way to find out is, as I said above, do it yourself
if parts look gone and if you can't repair, then replace!
Cheapest way to go and you'll know exactly what's gone into it.
In terms of what else to replace - it really depends on what else needs replacing. Best way to find out is, as I said above, do it yourself
if parts look gone and if you can't repair, then replace!Cheapest way to go and you'll know exactly what's gone into it.
AntHughes
Member
I would say do it yourself, its hard and it drains the effing life out of you at times but you learn the ins and outs of the old girl and you know everything is done to your spec and standard, it might take a bit longer but it will be worth it.
Ive seen galvanised bulkheads on ebay for 700, im gunna save up and get bulk head, chassis, axels and doors for mine. well that's the plan.
Ive seen galvanised bulkheads on ebay for 700, im gunna save up and get bulk head, chassis, axels and doors for mine. well that's the plan.
northmavern
Member
+1 wot Ant said.
Im 90% of my way though a 110 csw refurb.
I bought an '88 plate CSW that had previously been lifted onto a galvanised chassis a few years ago. Some years prior to that it had had a 200tdi put in. But the body, door and obviously the bulkhead were in a poor way.
Ive had the bulkhead repaired (not sure how much original is left given the number of holes and amount of rust on it) and dipped as too the sills and B pillars.
Ive bought 4x new GRP doors.
Prepp'd each panel and had them sprayed individually.
Sorted out a load of electrics
Reupholstered all the seating
etc etc.
It's taken nearly 6m mainly because of delays in getting the bulkhead and sills back.
Cost of sills £800 ish
Cost of Bulkhead £700 ish
Doors £1,000
Paint job £600
All the other bits and pieces will probably come to another £1,000.
It's doubtful that when Ive finished, she'll be worth what Ive spent (£c.9k) but Ive been enjoying it along the way, Ive had the chance to rebuild it in a way that suits how I want to use it (heated windscreens, removed the heater and installed an Ebershpacher I had instead etc etc), and it's been a lot of fun and a great education.
And when it's all done, its a galv chassis, galv bulkhead, galv sill'd, 200tdi station wagon. There's not a lot of them around.
Getting there:
Im 90% of my way though a 110 csw refurb.
I bought an '88 plate CSW that had previously been lifted onto a galvanised chassis a few years ago. Some years prior to that it had had a 200tdi put in. But the body, door and obviously the bulkhead were in a poor way.
Ive had the bulkhead repaired (not sure how much original is left given the number of holes and amount of rust on it) and dipped as too the sills and B pillars.
Ive bought 4x new GRP doors.
Prepp'd each panel and had them sprayed individually.
Sorted out a load of electrics
Reupholstered all the seating
etc etc.
It's taken nearly 6m mainly because of delays in getting the bulkhead and sills back.
Cost of sills £800 ish
Cost of Bulkhead £700 ish
Doors £1,000
Paint job £600
All the other bits and pieces will probably come to another £1,000.
It's doubtful that when Ive finished, she'll be worth what Ive spent (£c.9k) but Ive been enjoying it along the way, Ive had the chance to rebuild it in a way that suits how I want to use it (heated windscreens, removed the heater and installed an Ebershpacher I had instead etc etc), and it's been a lot of fun and a great education.
And when it's all done, its a galv chassis, galv bulkhead, galv sill'd, 200tdi station wagon. There's not a lot of them around.
Getting there:
Just had mine done, a mate of mines garage so labour was low but everything I took off needed replacing and the costs just kept rising.
Mine is a 1994 200tdi 110, got a galvanised chassis and bulkhead for it and we said 2 weeks, turned into a month and a total bill of around 6k all in but as I say mates rates so add another 3k to that easy.
Once stripped down it would have been silly not to replace things so basically everything was replaced.
All bushes
Bumpstops
Fuel tank
Sender
Fuel lines
Brake lines complete
Suspension
Brakes
Wheel bearings
Complete engine gasket set and service
Timing belt
Transfer box seal
Breather kit
Engine mounts
Exhaust
Windscreen is a bugger, seal was perished so tried to replace it, broke screen so had to have new screen and rubber.
Door hinges and spacers
Full bolt kit was £100 plus
P clips for brake lines etc
Wiring problems, bad earths everywhere
Replaced seat box as was rotton
Gearbox cowling a also rotton
The list goes on really, yes some of it could have waited but would have had to be done eventually, the more you take off the more you want to replace.
However, my landy is now awesome, I love it, yes I could have bought newer one to start with etc but I've had it with electrics, sensors, egr valves etc etc, mine for me is better than anything newer and worth doing but if I was to do it again I'd do it myself while I ran round in a banger and just ask for a little help with things.
Mine is a 1994 200tdi 110, got a galvanised chassis and bulkhead for it and we said 2 weeks, turned into a month and a total bill of around 6k all in but as I say mates rates so add another 3k to that easy.
Once stripped down it would have been silly not to replace things so basically everything was replaced.
All bushes
Bumpstops
Fuel tank
Sender
Fuel lines
Brake lines complete
Suspension
Brakes
Wheel bearings
Complete engine gasket set and service
Timing belt
Transfer box seal
Breather kit
Engine mounts
Exhaust
Windscreen is a bugger, seal was perished so tried to replace it, broke screen so had to have new screen and rubber.
Door hinges and spacers
Full bolt kit was £100 plus
P clips for brake lines etc
Wiring problems, bad earths everywhere
Replaced seat box as was rotton
Gearbox cowling a also rotton
The list goes on really, yes some of it could have waited but would have had to be done eventually, the more you take off the more you want to replace.
However, my landy is now awesome, I love it, yes I could have bought newer one to start with etc but I've had it with electrics, sensors, egr valves etc etc, mine for me is better than anything newer and worth doing but if I was to do it again I'd do it myself while I ran round in a banger and just ask for a little help with things.
