Vehicle & Technical > Defender

Fitting bulkhead

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V8MoneyPit:
I've modified a TD5 bulkhead to fit an earlier 90 with an LT77 gearbox. When I took the old bulkhead off, it had shims on one of the big bolts and one of the brackets under the sloped floor, but only 2mm or so.

When I've loosly fitted the new bulkhead, there are huge gaps between the brackets and floor. The bracket is adjusted as far back as it will go. Is there a difference here on the TD5 bulkhead. It doesn't look like it as far as I can see.

I've measured the chassis as best I can (new Richards item) and it seems OK.

Defender:

--- Quote ---When I've loosly fitted the new bulkhead, there are huge gaps between the brackets and floor.
--- End quote ---

I had the opposite. I had to remove some of the shims to get my TD5 bulkhead to fit.
Sounds like typical Land Rover build tolerances.  :lol:
One option would be to elongate the holes in the bracket so you can move it further back.

V8MoneyPit:

--- Quote from: Defender on August 12, 2008, 22:40:32 ---
--- Quote ---When I've loosly fitted the new bulkhead, there are huge gaps between the brackets and floor.
--- End quote ---

I had the opposite. I had to remove some of the shims to get my TD5 bulkhead to fit.
Sounds like typical Land Rover build tolerances.  :lol:
One option would be to elongate the holes in the bracket so you can move it further back.

--- End quote ---

And up!! We are looking at more than half an inch on the drivers side  :shock:

As an aside....
What is the best way to align the bulkhead? Presumably, it can only be done when the other panels in place?

tack43:
I recall reading somewhere to work from the back forwards, however, the bulkhead usually is the first bit fitted on all the rebuilds I've seen.

V8MoneyPit:

--- Quote from: tack43 on August 13, 2008, 12:01:51 ---I recall reading somewhere to work from the back forwards, however, the bulkhead usually is the first bit fitted on all the rebuilds I've seen.

--- End quote ---

I suspect that is basically right. I'll leave the bulkhead loose until the rear tub and sills are fitted. Then the doors can be used to set the vertical angle of the bulkhead.

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