 | Home > Maintenance & Modifications > Rusty Bulkhead strip and rebuild |
 
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92   
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Finished the seat box, So now onwards and upwards... The Bulkhead !
What a mess !  Click image to enlarge Click image to enlarge Click image to enlarge 1984 300TDi hardtop Stornoway Grey 1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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22nd Mar 2017 9:10pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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The landie ( with 9 months MOT ! ) came with some repair panels 'placed ' in position
the galvanised ones in the photo Click image to enlarge Obviously a pattern part.... total rubbish ! holes in wrong place and made of 0.7mm steel ! So made up a couple of plates in 1.5mm steel to weld in, bare metal ones in picture Then I had to drill some square holes  in them for the plastic jobbers for the mounting screws,
Click image to enlarge and then cut out the old steel , leaving a nice flange to weld to Click image to enlarge Click image to enlarge Then trim till the repair sections fit , ready to weld tomorrow ! Click image to enlarge Going to have to fab up a side panel as well, or it might be a bit draughty. 1984 300TDi hardtop Stornoway Grey 1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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22nd Mar 2017 9:20pm |
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| Mash Member Since: 09 Feb 2015 Location: Guernsey Posts: 1674  
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Good metal bending skills, keep up the good work.
 90 wolf - Jasmin http://www.defender2.net/forum/topic39408.html
90 V8 - Maggie http://www.defender2.net/forum/topic42564.html 110 TD5 - Buggsy http://www.defender2.net/forum/topic59029.html 52HG25 lightweight https://www.defender2.net/forum/topic72342.html D3 Hse - Fiona Capri 2l S - Anna Think I might have a problem............ |
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22nd Mar 2017 9:25pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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Welllll............. actually had the local metal shop cut and bend them, my Clarke bender isnt up to it !
 1984 300TDi hardtop Stornoway Grey
1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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22nd Mar 2017 9:30pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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I lined everything up, drilled some holes to weld through, and used bolts to temporarily hold it in position ready for welding
Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Looking better already 1984 300TDi hardtop Stornoway Grey 1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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25th Mar 2017 6:38pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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Started today with some KAD.... Kellogs aided design ! 
Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Let the welding begin Click image to enlarge Click image to enlarge Some strenthening on the floor , dont think it is neccicary Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Floor all finished, quite pleased with the result, considerably stronger than the floor in my 300TDi Click image to enlarge Click image to enlarge Now just the other patches to do.... 1984 300TDi hardtop Stornoway Grey 1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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26th Mar 2017 4:46pm |
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| Outlaw1 Member Since: 11 Aug 2016 Location: east sussex Posts: 266  
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Nice work Jim
Have you tried the frosty KAD system in the winter months |
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26th Mar 2017 6:36pm |
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| Thon Member Since: 22 Nov 2015 Location: Salisbury Plain Posts: 696
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Always pleasing to see some well-executed fabrication
For fabrication junkies these guys are brilliant ... http://www.badobsessionmotorsport.co.uk/ca...ect-binky/ Top fabbing  |
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26th Mar 2017 7:56pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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Yes, been watching the series, those guys are amazing, and such well executed video ! 1984 300TDi hardtop Stornoway Grey
1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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26th Mar 2017 9:33pm |
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| Thon Member Since: 22 Nov 2015 Location: Salisbury Plain Posts: 696
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I think the effort they put into fabrication is matched by that put into their production skills. Both at a very high level.
Really amazingly entertaining. It's the only subscription I have on Youtube that i'll drop whatever i'm doing to watch. I used to work with a top class fabricator who now manages work on Bristols and it's artistry when it gets to that level, and the sarcasm is world-class |
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26th Mar 2017 9:38pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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Nice to get some appreciation, Yes, agree about the rusting ! I am getting the bulkhead galvanised, and then my plan was to fill the ' strengtheners' with expanding foam to keep the water out before painting over. It was surprisingly strong ( in 1.5mm steel) before the strengtheners. 1984 300TDi hardtop Stornoway Grey
1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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27th Mar 2017 9:44am |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 572  
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Are you sure, that the foam will not absorb water? "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo
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27th Mar 2017 11:17am |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5738 
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Maybe cap off the ends and leave a hole for the galv to get in, then before painting seal with seam sealer and fill with cavity wax then seal the holes with grommets? 1999 Defender TD5 110
Regards John M0VAZ Econet Station 48 no clock |
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27th Mar 2017 12:38pm |
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| Jim G Member Since: 21 Jul 2014 Location: Ormskirk Posts: 92
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Good idea, I think the foam is waterproof though , it floats, so probably doesnt absorb water, plus I will paint the ends and so seal it.... ask me in 5 years how it worked !
 1984 300TDi hardtop Stornoway Grey
1984 200TDi hardtop..... soon to be a V8 .. but which V8 ? 1974 DAF T244 4x4 wagon converted to a motorhome 1976 Jaguar XJC with supercharged engine |
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27th Mar 2017 4:43pm |
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