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Procta



Member Since: 04 Dec 2016
Location: Sunderland
Posts: 4937
United Kingdom 
Woody3 wrote:
Thanks for the replies chaps.

After careful consideration, I've decided to keep with Eastnor Green. The 200tdi is going to stay for now too. I do tow occasionally, so some extra grunt would have been nice. Having said that, it's a keeper, so looking long term, should the 200tdi last at least another decade, I guess the next conversion will be to electric.

Anyway back to the present...

Just got the bulkhead to remove now (the rear tub will be repaired insitu). I'm at a crossroads with the bulkhead. I have three maybe four options.
Option 1 - repair and galvanise existing bulkhead, which is straight, but gone on the corners and footwells
Option 2 - repair and galvanise a Td5 bulkhead that I have which is rust free, but buckled, with accident damage on the o/s door pillar and corner.
Option 3 - buy a new galv'd bulkead at £1650 Shocked
Option 4 - find a straight, honest bulkhead and galvanise it myself.

Photos to follow, but thoughts on the bulkhead options would be much appreciated!


How much do you want to spend? if i had the budget, i would buy a new galv bulkhead and then repair the old one and sell on later Thumbs Up If you have the skills i would just repair the old unit and galv it Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

Success is 90% Inspiration and 4 minutes Preparation # you can make it!
Post #832119 19th May 2020 11:04pm
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L90Andy



Member Since: 29 May 2014
Location: Stratford-Upon-Avon
Posts: 716
United Kingdom 2006 Defender 90 Td5 SW Zambezi Silver
Following this rebuild Woody Thumbs Up
Love to see serious work being done and look forward to watching the progress. Instagram: l90andy

2006 Land Rover 90 TD5 CSW Silver Edition

My 1984 Ninety: http://www.defender2.net/forum/topic56071.html - SOLD!
My 2015 Defender: http://www.defender2.net/forum/topic39625.html - SOLD!
Post #832341 21st May 2020 9:45am
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
Can't believe it's been nearly 3 months since my last post.

Bit of an update:

After spending a week or so shot blasting the td5 bulkhead, I took it to a couple of metalwork fabricators/bodywork shops and neither wanted to take on the job of straightening it. So, plan B took over, and instead of wasting another week shot blasting the original bulkhead, I sent it off to the paint strippers who are dipping it this week, hopefully!

Then it's a case of buying the replacement panels and finding a good, local welder.

Other progress:

Seat box now repaired and is ready for painting.

Ordered new clutch slave cylinder and associated pipework, due to a slow constant leak. Unfortunately the clip on the clutch rod broke, so I now have the awful task of fitting a new one.

Galvanised turrets purchased and are being replaced.

Fixing the dents in the osf wing - managed to source the front headlight section of the wing, just looking for the side part of the wing now.

Need to do a couple of repairs on the rear tub. I will upload some more photos.

That's currently where I am, but at least things are being put back together now!
Post #850522 17th Aug 2020 3:33pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
Got my bulkhead back!

The paint strippers have done an amazing job. Surprisingly, it's not as bad as I was expecting! From my initial inspection, it looks like it needs both footwells replacing, both top corners and the foot to the o/s door pillar.


Click image to enlarge

Will do a better inspection later this evening.

Oh and the clip that attaches the clutch rod to the clutch fork arrived today, so that'll be tonight's frustrating job! Laughing
Post #851294 21st Aug 2020 3:56pm
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769
England 2004 Defender 110 Td5 CSW Bonatti Grey
Doesn’t look too bad Thumbs Up just noticed the pic by your name, if that’s guy Martin my mrs was chatting to him last week about some work he’d got her work to do for him Thumbs Up Ray
My build thread
http://www.defender2.net/forum/topic17615.html
Post #851302 21st Aug 2020 4:31pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
Procta wrote:


How much do you want to spend? if i had the budget, i would buy a new galv bulkhead and then repair the old one and sell on later Thumbs Up If you have the skills i would just repair the old unit and galv it


Sorry Procta - I didn't realise that I hadn't responded! I looked into buying a new one, but I just couldn't find a reliable source. Hopefully I have better luck sourcing a skilled mobile welder that is prepared to take on the job of repairing mine.
Post #851332 21st Aug 2020 9:05pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
mk1collector wrote:
Doesn’t look too bad Thumbs Up just noticed the pic by your name, if that’s guy Martin my mrs was chatting to him last week about some work he’d got her work to do for him Thumbs Up


It is indeed! Thumbs Up
Post #851353 21st Aug 2020 10:17pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
A further update!

The bulkhead is in at the local Land Rover specialists for repair. I'm hoping to have it back and galvanised before Christmas!

I've fitted a complete new LOF clutch kit and associated pipework and the gearbox has been reinstalled! When I removed the gearbox I noticed that it was only connected to the engine with half a dozen nuts and bolts on the top half of the bellhousing! It was the same for the flywheel housing too! I have fixed this by using countersunk bolts on the bottom of the flywheel housing and tapping the existing holes for the bellhousing.

Before (I wondered where all my clutch fluid was leaking too!):

Click image to enlarge

After:


Click image to enlarge

Gearbox being installed - have I got enough straps?


Click image to enlarge


Click image to enlarge


Click image to enlarge


Click image to enlarge

And in

Click image to enlarge

Last edited by Woody3 on 30th Nov 2020 2:02pm. Edited 1 time in total
Post #870470 30th Nov 2020 1:35pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
You'll also notice my galvanised chassis is now painted black! I've used Coroless paint system for this.
Post #870475 30th Nov 2020 2:00pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 10502
England 
You can never have to many straps Wink taking shape nicely there Thumbs Up 1996 Golf Blue 300Tdi 110 Pick up. Keeper.


Clayton.
Post #870640 30th Nov 2020 10:41pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
A well overdue update!

So what's been happening...

Progress hasn't been as quick as I'd like, mainly due waiting since September for my bulkhead to come back from the repairers and work commitments.

However, last week, the bulkhead came back! Unfortunately the repairer decided to seam seal, prime and Raptor paint it prior to collection, not realising I was sending it to be galvanised. I think you'll agree he's done a cracking job though!

Original state:


Click image to enlarge

Back from the welders buy prior to the re-strip:


Click image to enlarge

And today after the re-strip:

Click image to enlarge

Other processes that have happened behind the scenes:
- stripped, rebuilt (with various new parts/fixings) and painted the front axle
- cleaned and painted the front half of the chassis

Next steps:

- Send bulkhead and various brackets/parts off to the galvanisers.
- Buy paint and spraying gear!
Post #902958 13th May 2021 11:58pm
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JOW240725



Member Since: 04 May 2015
Location: Suffolk
Posts: 7873
United Kingdom 2012 Defender 110 Puma 2.2 XS CSW Orkney Grey
Great work! Thumbs Up James
MY2012 110 2.2TDCi XS SW Orkney Grey - http://www.defender2.net/forum/topic43410.html
MY1990 110 200TDi SW beautifully faded Portofino Red - https://www.defender2.net/forum/post743641.html#743641
MY1984 90 V8 Slate Grey - https://www.defender2.net/forum/post744557.html#744557
Instagram @suffolk_rovers
Post #902964 14th May 2021 6:27am
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Dinnu



Member Since: 24 Dec 2019
Location: Lija
Posts: 3203
Malta 2012 Defender 90 Puma 2.2 CSW Santorini Black
Great rebuild Thumbs Up

Just a remark, perhaps you want to sort out before sending the bulkhead to the galvanizers, it seams to be missing the 2 brackets (one on either side) that bolt the inner mudguard to the bulkhead.



 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black
Post #902974 14th May 2021 8:24am
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mrfirepro



Member Since: 07 Nov 2020
Location: kent
Posts: 219
United Kingdom 1996 Defender 90 300 Tdi HT Bonatti Grey
I recenly galvanised my bulkhead and then preped it and painted it, and overlooked taping and dieing all the threads, now I'm doing it with nice pristine paintwork with swarf and cutting oil everywhere, not my smartest move.
Post #903030 14th May 2021 3:44pm
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Woody3



Member Since: 13 Jan 2010
Location: Derbyshire
Posts: 415
United Kingdom 1989 Defender 90 200 Tdi HT Bronze Green
Dinnu wrote:
Great rebuild Thumbs Up

Just a remark, perhaps you want to sort out before sending the bulkhead to the galvanizers, it seams to be missing the 2 brackets (one on either side) that bolt the inner mudguard to the bulkhead.





I wondered how long it would take for someone to spot that! They are in my "box of brackets/parts to galvanised" Very well spotted though! Thumbs Up

Yes, I will be re-tapping/prepping holes etc before painting - can't imagine that being fun to do afterwards Crying or Very sad

Hoping to pick up the paint this week - a (very) slight divergence in colour scheme... Whistle
Post #903662 18th May 2021 12:12am
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