 | Home > Technical > Galvanising bulkheads - distortion |
 
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4388  
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Good question was wondering the same thing yesterday  |
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27th Jul 2013 10:16pm |
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| Mountain_man Member Since: 09 Dec 2011 Location: Right side of Offas Dyke Posts: 756 
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Here is one I did earlier....
 Click image to enlarge Had it bead blasted which showed up all the thin metal and removed rust. Then replaced any suspect areas with new steel, 2 new footwells welded in. As much seam sealant removed with a point as possible. Then added the 3mm walled box across the outrigger mounts to stiffen the whole thing. Finally added the gate hinges to the windscreen fixing holes in order to give the works a good hanging point. Rightly or wrongly I thought it would be better lowered into the galving tank vertically rather than laying flat as the structure would heat gradually from bottom to top rather than all at once. In any case I had zero distortion and the whole thing, once everything was fitted back on to it bolted onto the new chassis without levers or hammers |
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27th Jul 2013 11:07pm |
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| GUM97 Member Since: 05 Feb 2012 Location: Cheshire Posts: 3555 
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I've got one on my 90, came from Ashtree
http://www.ashtreelandrover.com/ An engine to TDi for! "Land Rover- Proudly turning drivers into mechanics since 1948" |
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28th Jul 2013 8:29am |
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| Litch Member Since: 10 Mar 2013 Location: Oxfordshire Posts: 759 
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Had mine done a couple of months ago and no problems at all with the process.
Bulkhead was in practically perfect condition to start with so no worries of internal corrosion (I had thoroughly Waxoyled it 12-years previously and then looked after it, also I have no carpets, mats or sound deadening so nothing to retain moisture). Bolted a length of box-section between chassis mounting points. Ground away the welds fixing vent-flap mesh into position enabling mesh to be removed. Drilled several additional holes into box-sections (not visible when assembled) so whichever way it was dipped there would be somewhere for gasses to escape. Took lots of photos and made detailed drawings / measurements of all holes before dipping so I could accuratly identify where even the smallest of screw-holes had been filled with zinc. On return from the galvanisers decided to trim the nylon inserts where necessary rather than filing the holes thus avoiding the risk of exposing bare metal (obvioulsy excess was knocked off but I didn't enlarge any holes). All threads were re-tapped. Worst part was cleaning excess zinc out of sleeves for vent-flap pins, found a Dremel worked best and having established this it took only a matter of minutes. Vent-flap mesh has been bonded into position. I plugged all the holes, turned it upside down and filled it full of Waxoyl (just like last time), in the recent heat-wave has it been dripping out as expected having coated every internal surface on the way. Front & underside of footwells have been undersealed and Gwyn Lewis mud-shields fitted. It hasn't been painted as I prefer the galv look and it matches the capping etc. By the time all the panels are in place there isn't actually much on show. Flat surfaces around the footwells have rippled slightly (as expected) but there was no distortion and it fitted back into place without any problems. No sealant necessary along seams etc as the zinc has filled everything. Best bit. Cost £144 inc VAT for collection & delivery (50-miles from galvanisers), preparation and then galvanising. This wasn't just the bulkhead either, I also had the battery-box done, rock-sliders, sills and 20 assorted parts & brackets (seat-belt mountings, steering column brackets, fuel-tank mounting, tunnel adaptor etc). [URL=] Click image to enlarge[/URL] [URL=] Click image to enlarge[/URL][/img] Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated  ONE LIFE, GET IT! |
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28th Jul 2013 9:14pm |
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| Andy80 Member Since: 31 May 2013 Location: Essex Posts: 484 
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Thanks litch , the tips and advice will be useful indeed
 Working towards Carry on camping! |
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28th Jul 2013 11:12pm |
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