Mud-club
Vehicle & Technical => Defender => Topic started by: 90Mike on January 11, 2009, 14:47:30
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Hi guys i am looking at swapping the disco for a 90 in the near future and have been looking at a few on ebay. There seems to be 2 common corrosion faults rear x member and bulkhead, I am not going to give the disco away but at the same time i dont mind a bit of work has any one replaced these themselves? and what kind of job is it or anyone got any photos of there rebuild :)
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Replacing a bulkhead requires a major strip down & rebuild. However the bulkheads are repairable in situ, as long as they aren't too badly corroded.
The X member is a fairly simple job to replace & easily done in a long day by competant welder.
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bulkhead to replace properly is approx 4 day s work and thats if you know what u are doing, repair, all panels can be bought.
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My 90 is going on the bulkhead corner. How successful is an in situ repair? I've seen those corner panels at shows but always thought they were a bit of a bodge!
Don't care too much as when i have the time/money i'll do a ground up rebuild.
Nick
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did the top corners and pillars on mine, top corner is easy, undo windscreen bolts, wedge the screen out of the way and work away, if you are luck the dash can stay in place. Pillars need the doors off, the replace the captive nuts (not worth reusing them) mine looks tidy.
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anyone got any photos of there rebuild :)
Have a look at my step by step description of how to make a TD5 bulkhead fit a Tdi in THIS POST (http://www.mud-club.com/forum/index.php/topic,55219.0.html)
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I did mine in situ. Its not perfect but much better than it was and will do a good few years now I think! You may as well try, you have nothing to lose but a few quid on repair bits after all!
Some pics from mine...
(http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v105/230/3/722575676/n722575676_393397_9547.jpg)
(http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v105/230/3/722575676/n722575676_393398_64.jpg)
(http://photos-b.ak.fbcdn.net/photos-ak-sf2p/v105/230/3/722575676/n722575676_393401_1841.jpg)
(http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v105/230/3/722575676/n722575676_393404_3246.jpg)
(http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v105/230/3/722575676/n722575676_393407_4525.jpg)
Go on, just do it..
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Nice job :clap:
Did you buy the complete upright :-k
I am just having my replacement bulkhead galvanised :afro:
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A big thanks for all your replies and for the great photo's ;) at least i know that a repaired bulkhead can be made to look just as good as a factory item with a little time, i think this will be the way forward when i find the right motor :D
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Its been a while since i did mine but I think I bought http://www.paddockspares.com/pp/DEFENDER/Chassis/Front_door_pillar_-_LH.html
I have no doubt I will have to replace the bulkhead eventualy but I reckon it will take a few more big patches over a few more years yet! :D
Cheers,
Mike
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bulkhead to replace properly is approx 4 day s work and thats if you know what u are doing, repair, all panels can be bought.
4 Days? does that include a chassis swap and an engine rebuild! lol