Thread: defender tub replacement and galvanised bulkhead

Nice work. Which galvaniser if you don't mind me asking?

it's Hartways in canningvale, off bannister rd. they also have another workshop in naval base

Thanks.

Originally Posted by Bigmark

...they also have another workshop in naval base

Well, they have a block of land at least...

No Cookies | Perth Now

Having started to look at the possibility of doing this as well, I have noticed that there is double skin in the footwell, and the ribbing on the engine bay side creates cavitys. Did you drill holes for these to be coated and drain?

Some here have mentioned welding will cause problems. Well as a budget is always a problem, finding a bulkhead with NO rust repair needed is hard or expensive. What methods can be used to help control warping etc? Is there anyway of stress reliveing the welds prior to HDG?

Originally Posted by uninformed

Having started to look at the possibility of doing this as well, I have noticed that there is double skin in the footwell, and the ribbing on the engine bay side creates cavitys. Did you drill holes for these to be coated and drain?

Some here have mentioned welding will cause problems. Well as a budget is always a problem, finding a bulkhead with NO rust repair needed is hard or expensive. What methods can be used to help control warping etc? Is there anyway of stress reliveing the welds prior to HDG?

Serg, Weld repairs are not a problem. The welds will just rise up a bit when galvanised. I can take some pics if you want. Even series bulkheads have some double skinned areas. The gal just coats and seals the area, and you won't have any problems,

Pics are always good

What if rust/corrosion has started in between the skins and is not visible from the outside etc, I thought it might get trapped and continue with condensation etc?

Originally Posted by uninformed

Pics are always good

What if rust/corrosion has started in between the skins and is not visible from the outside etc, I thought it might get trapped and continue with condensation etc?

Zinc is a sacrificial coating, so no need to worry about that.

Originally Posted by uninformed

Pics are always good

What if rust/corrosion has started in between the skins and is not visible from the outside etc, I thought it might get trapped and continue with condensation etc?

I will take some firewall pics and profile pics, but this is what I have to hand at present.

Bullbar welded, welds ground flush, then (steel) shot blasted.

http://i124.photobucket.com/albums/p...y_parts051.jpg

After galvanising

http://i124.photobucket.com/albums/p...ne_2010022.jpg
The shot blasting would have stress relieved the welds, but did not stop them rising up (or reduce it).


These welds were also ground flush before galvanising

http://i124.photobucket.com/albums/p...ne_2010019.jpg


EDIT: This article suggests it is not the welds rising up, but rather a thicker coating of zinc induced by higher silicon content in the weld area (due to welding rods or grinding discs). http://www.zinkpower.com/media/files...glisch/2_9.pdf

All my welding was done with a MIG, and I did plenty of cutting and grinding on non weld areas - without the same thickening... So it sounds dubious. I will need to check the Si content of my mig wire.