Hi! I have posted on here before but in the Discovery forum and received great advice.

We have a Series 3 (learnt to drive in it!) which is running great and is basically solid apart from rot around the vent flap panel. Parts of it are ok but driver’s side top and passenger side side have gone in holes. The rear skin of the bulkhead seems fine, lower bulkhead is fine Too, foot wells all fine. The rot set in behind the rubbers, found it when we removed them.

I have seen bulkhead vent repair panels but to fit these does the dash/roof/windscreen need to come out/off? I’m guessing they don’t go over the top? We know someone who does welding but only has an arc welder... just wondering what the best options are bearing in mind the rest of the bulkhead looks good.

Thank you everyone!
George

Assuming you want to do a good job, yes, bulkhead has to come out.

If it were mine I'd cut loads of small bits and mig weld them on, you don't need to remove the bulkhead if the rots only on the outside. An arc welder on that will just cut holes in it.

Thank you very much for your replies. Does the whole bulkhead have to come out for the vent flap panel repair from YRmit? Yes the rot is only in the outside.

You might get away with just removing the bonnet and screen if you use a mig.

Don't even think about taking out the bulkhead its a huge job and will lead grinding off bolts and even more repairs. Your's doesn't actually look that bad I'd get a cheap panel from Paddocks and cut out the bits you need from it rather than chopping the whole bulkhead about.

Miliput

Bobsticle said:

Miliput

Click to expand...

Yes well when I said if it was mine I'd mig repairs in what I'd actually do is use 2 part metal repair epoxy....... But then I'm not too precious about it.

I've recently done alomost exaclty the same holes in my S2A bulkhead, cut small pieces and set them flush then welded in with MIG, All done assembled and outside (I don't have a garage). My advice - Cut small patches, you can always put a big repair plate in later.
Get a fine cutting disc and cut each hole to decent metal, try to get striaght edges.
Rub tape over the hole to get an outline, then put the tap on the new metal and cut the exact shape, hold it in place with magnets.
Get an inverter MIG, about £200 if you shop around, its the only way to reliably do thin metal. Gasless worked fine for me (especially as I was outside).
You are aiming to just melt both edges.
I would stongly advise against taking the bulkhead out, its a huge job and a lot more will get damaged. You could reasonably do all those holes in a day,, you will get better are you go, but the bulkhead out will add 40 hours to that at least.

The inverter mig will more than pay for itself and gasless with these digital control migs is way different to on a AC welder..

Here is mine, about 1 hour from start to finish working outside, gassless mig. OK yours are bit more fiddly, but its all doable. Be sure to have a fire watcher and CO2 exstinguisher with you as there may be waxoil in the bulkhead.