front outrigger/bulkhead bolt trouble!!

[JimP]

After removing the bolt that goes throught the bulkhead bottom mount and front outrigger in order to fit my new roll cage supports I'm having a right pain in the a**e trying to fit it back, seems that the holes dont line up, the bolkhead mount seems to be approx 15 degrees out to the outrigger (they dont line up, so I cant get a bolt it! I've managed to get one through by persuading it with a dirty great hammer, but so much so that the thread is ruined and I cant get a nut on the end! so thats got to come out again 

anyone experiences this?

any tips???

Cheers

Jim

[V8MoneyPit]

If they came out OK, it sounds like the bulkhead has moved. The bolts are the main support for the bulkhead although the wings and footwell supports should hold it roughly in place assuming they are in OK condition.

Is the bulkhead hole lower than the outrigger? If so, try sticking a jack under the bulkhead.

Do your doors still line up the same? Again, if the bulkhead has moved, they will not open and close well.... if they ever did on a Defender!

[Mutz]

A mate had this problem after repairing a bulkhead and respraying it!!

Was about 25m/m wider than it should have been!!!

The wings luckily had been taken off and we got a ratchet strap to pull the bulkhead back to the original holes on the chassis, popped the bolts back in then released the pressure off the straps.

Would be awkward with the wings still in place tho!!!

Land Rover tolerences im afraid!!!


Graham

[Mutz]

Did you sort it? If so How?

[JimP]

Not yet, ordered some new bolts and waiting on them, did the other side yesterday, all was fine on that side! took my 1/2 and hour and all finished!

I can get a M10 bolt in and through so I dont think it's out by a huge amount, going to fill the hole with grease I think and hope I can smack it in without ruining the thread on another bolt!

Fingers crossed the bolts will arrive today so i can have a go later

Jim

[V8MoneyPit]

How about getting a short length of 12mm round bar and tapering one end a little. Smack that in first. File off any burr lifted by the hammering. Then drift the new bolt through behind it. It might reduce the damage to the thread.

Or you have to get a large pry bar somewhere to heave it over while you are inserting the new bolt. Just smacking it through will always damage the thread.

[JimP]

I'll give that a try I think, use the old bolt maybe as a guide and see if it helps.

fingers crossed!!

[paulnb57]

Grind a 45degree angle on the end of your new bolt it may help to guide it in...........

[MuddyMike]

Thack the new bolt in, clean up the thread with a thread file, fit nut, jobs a goodun.

Mike