Well time for the next installment , first up tub bulkhead removal I'd looked round the net saw the manufactured ones I didn't want to remove it totally thought I can make one for a few quid lets have a go . So firstly removed the top rail .
Then decided I was going to use some 40x20 I had brought for the roof rack I was making , fitted nice and looked okay .
Then cut it out where I wanted it .
Then slit the cross and side tubes so they fitted over the lip that was left .
Then a test fit .
Didn't like the corners so cut the corner piece so it fitted flush in there and decided fixing wise , the frame would be welded in situ , sides would be welded to the tub cappings and the bottom rail was drilled through rivnuts fitted the screwed down with counter sunk head screws . So you ended up with this . I did put some closed cell foam in between the bottom rail and the tub .
Next up was to move the fuel filler as if you remember from earlier I'd fitted a TD5 tank , the filler neck frame was brought from YRM.
So first up was mark out the hole , measurements were taken from a TD5 90 which was the father-in -laws .
You'll notice there's 2 lines the cut was made on the inner one with a plasma cutter ( which I brought from ebay for £200 , well worth the investment) the outer line was the appeture so the first line was bent back to make the return .
Like so ,the back was cut out also then the frame test fitted , the holes were for plug welds , it was also bonded in to seal it well .
Welded an sanded flat . Next a small frame was made to secure the filler to the tub inside and riveted in place .
The old hole was then filled , a plate was cut to make a snug fit then welded in with small stiches and was smothed over with filler later to make it look flush .
The inner frame was removed but not fully as it helps strengthen the panel . Next was the access panel for the fuel tank sender , means you can change the sender without dropping the tank , makes life a lot easier . So the floor was cut at the correct distances , which I found on the internet , and edged with alli strip . You have to remove part of the floor strengthener but it looked fine and I'd upped the floor thickness to 3mm anyway.
the side strips were then riveted in place .
And the cut out piece was used as the cover plate .
The plate was drilled straight through and rivnuts fitted to the straps underneath so it could be fitted down and ended up like this .
Next up is the seat box rebuild .
cheers Ian