Vehicle & Technical > Defender

New Bulkhead tdi-td5

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zulublue:
Why dint you find a good 200/300 bulkhead, OK it may take a bit of time, then have it shot blast and galvanized?

L90OOK:

--- Quote from: zulublue on February 20, 2009, 10:54:41 ---Why dint you find a good 200/300 bulkhead, OK it may take a bit of time, then have it shot blast and galvanized?

--- End quote ---

I did exactly that  :afro:

crazymac:
I've got a brand new TD5 Bulkhead in my garage that I could be persuaded to sell!!

Ridgeback:

--- Quote from: crazymac on February 20, 2009, 23:10:28 ---I've got a brand new TD5 Bulkhead in my garage that I could be persuaded to sell!!



--- End quote ---
Thanks for the offer but I'm looking for one with all the dash and heater parts still on

Nobber:
its [throw it] easy to fit a new one , there are one or two differences.
the td5 bulkhead (dash panel assembly , the bulkhead is actually the bit behind the seats) will need the gear box tunnel cut a bit (i have been told there is a wide tunnel version?) by placing the diaphragm against it and marking it all out then grinding it and drilling the new holes for the diaphragm to bolt to.
at this point it would be wise to tack weld some captive nuts for the diaphragm bolts to fix to , its fiddly otherwise.

the td5 wiper mechanism is different , i had to drill out holes to bolt the motor in then drill out holes in the top to fit the wiper rod thingy , its very self explanitary when you have both bulkheads side by side.

the steering is different so the hold where the steering rod goes through needs widened , only by very little.

the fuse box is situated in a different place so you will need to drill a hole for the main harness to go through into the engine bay.

the td5 heater , i think was a different size? cant remember now.

you will need to dress the new bulkhead with bits , plastic passive nut thingys to screw the dash to and riv nuts to bolt the steering and heater to.
you will need captive nuts for the wings and the door hinges to screw to.

get a parts diagram with the bulkhead fittings and part numbers , the bits cost pennys but will make life so much easier , also you dont want to be held back for a week due to not having a riv nut worth 5 pence that holds your steering together.

a good idea would be to get some tiger seal to seal it all up before painting and then wax oil it before installing it.
get new heater seals , you will regret it if you dont come next winter.

i cant think of anything else off hand except you wont be able to do it properly without the parts book diagram and part numbers and if you dont do it properly you mighty regret it.

all in all though its a very easy , cheap alternative to having a crumbling bulkhead.
buy genuine though , dont go to crappocks or the like for a brickpart part , genuine from a main dealer usually works out cheaper then a sh!tpart one and unlike a sh!tpart one it will actually fit.


if you plan to do it and need help just ask , ive got loads of pics of the mods as well if you need to see anything.

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