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Went off on holiday for bit but back at today and managed to fix the welder issue I had. If you have a Clarke mig or other check your wire spool carrier pieces. Mine had a load of ridges which given me no end of feed problems. So today I filed and sanded them down the difference is astonishing...

@A1203 I think you are describing the strengthening channels in the original footwells that are not in the replacements and thus people weld on square tubing on to the underside. I do not have that as I used 2 mm thick steel sheets for my footwells which is super strong.(I hope)

Did you have any loss of zinc where bolts connected angle to bulkhead? In my head if i use a angle through the feet i will not any zinc into the hole of the bracket or where the angle butts up to the side. Can you explain how you over came this. Looks really nice!

Where it attaches to the feet did it stop the galv getting in?

I dont think I will use one to be honest, more worried about where the venting holes at the corners should be drilled I want them on the inside of the cabin.

The bulkhead has some odd aluminium rivets which appear to not be attached to anything unless its inside. Can someone shed some light on whether I can remove them as I will be galvanizing this week. Thanks

Not much to report other than lots of drilling, welding and filing square holes on the bulkhead. Sent bumper, capping and door sills to blasters. Made some rear door corner brackets today and started repairing the capping.

Weekends! In all seriousness, I am am dreading putting it back together as I took it apart so long ago I have no idea where things go:-)

Wow! you dont live far from me, what is your daily rate! (although I guess your busy now)

I had a look around for a part number but cannot find one. It seems the heater is one part. But it is the bracket at the bottom of the heater which connects to the top of footwell. This a image from google...

Thanks for replies, I did speak East Anglian, and I'm going to do the rear capping and wheel arch liners and door sills at the same time can do up to 50kg for 90 quid inc vat seems like a good price just gotta weigh everything.

My Heater bracket is completely rusted away and I am looking for a new one on the WWW but the only site which seems to sell them are out of stock. http://www.thelannydoctor.co.uk/products/43-defender-galvanized-heater-bracket.aspx Does anyone know where I can buy one or kindly give me...

I made the footwells from 2mm sheet so has a lot of strength, If I run a angle between the feet to keep it true, what happens where there is no way for the zinc to flow over the feet as there is a bolt running through it? I guess it might be better to tack weld across the inner side of the...

I want to galvanize my bulkhead and wondered if anyone had recommendations of a company in Hertfordshire or in East Anglia. Also wanted to ask for any tips or tricks to keep it from bending etc or general info I should be aware of. Many thanks

Made the wing brackets this morning as old ones looked pretty rusty. Measure, cut, bend and drill, primed. Put the door back on just to make sure all is well. Layed out the stencil I made previously. Got busy with my drill and cutting disk. Previous foot well for hole reference. Going...

.:)

Super scorcher today! Wife busted her ankle last Saturday so didn't get to weld on Sunday so got to suffer in a tin roof cramped garage playing with hot metal. Got footwell positioned and welded in and ground down the plug welds. Welder is really not happy it does not feed out wire smoothly...

Sorted out the foot and welded It into place. Appeared my jig had slipped so put the old foot back on and aligned the holes i had drilled out for the spot welds. Re tightened jig and replaced new foot, not exactly the same but nothing a file didn't fix. After that I spent an age getting the...

Wow - I wish I had a F1 garage to spend my weekends, instead of the cramped mess I have:-)

Very nice! Gives me inspiration to keep going :-)