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Thread: Tdi 110 bulkhead replacement - who's done one?

  1. #1
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    Tdi 110 bulkhead replacement - who's done one?

    Hi all,

    So there's rust in my firewall.. it's not too bad, but it's not going to get any better. I'm not too fond of the idea of having patches around the place, so I'm looking at a bulkhead replacement sometime in the near-ish future.

    Who's done one? And how much did it cost? Any recomendations on bulkheads or shops to do the work (located SE Qld)? The car is a 1995 tdi300 110.

    There's a picture attached of the main rust I've found - driver's side, upper bulkhead, on the seam where the upright bit joins the angled bit. In this area, theres a strip a few cms across that I can poke a screw driver through, and some pretty deep corrosion about the size of a 20c coin. The only other areas I've noticed are a small area where the paint is bubbling around the bulkhead bracket (pas. side), and the area around brake master cylinder bracket is a bit crusty, but it seems to only be surface rust (had a good poke around with a large flathead screwdriver). With this in mind, any thoughts on how urgently I should deal with the bulkhead?

    Keen to hear any thoughts, cheers!
    Attached Images Attached Images

  2. #2
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    My thoughts would be to fix what you have, it doesn't really look that bad.

    In fact, if you did remove it to fit another, I think you'd still be miles better off repairing that one once it's out.

    It's a bit of a job to remove and refit, and there are some pretty good rust treatments available.

    If you wanna sell that one... I'll buy it and fix it!

    Cheers
    James

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    Quote Originally Posted by shack View Post
    My thoughts would be to fix what you have, it doesn't really look that bad.

    In fact, if you did remove it to fit another, I think you'd still be miles better off repairing that one once it's out.

    It's a bit of a job to remove and refit, and there are some pretty good rust treatments available.

    If you wanna sell that one... I'll buy it and fix it!

    Cheers
    James
    Appreciate your response, that's good to know! The car's currently at British Off-Road getting a full service and a few other things, so I'm getting them to do a comprehensive rust check as well. I suppose if the rust is pretty much isolated I'll look at reapairing. If it's just a few spots that'll be much cheaper than a new bulkhead... I'd assumed that once spots like this start showing up, there'd be spots in a few other places as well, and by the time you've got all the rust out of it you'd be better off getting a gal bulkhead and painting it.

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    Others of course may have a different opinion, and you'd need to ascertain the extent, but there wouldn't be many pre 05 defenders without at least that much rust, I'd definitely be fixing it if its only those spots.

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    My 200 tdi is 30 years old. There was corrosion in the passenger footwell in the plate facing your toes. This was easily replaced/repaired. The corners of thebulkhead just outside of the windscreen block/hinges was beginning to rust. You can get repair corner pieces or you can just repair the corners. By "you" I mean the garage. Everything else bulkhead wise is solid so that is why these repairs were done. On the other hand when the series 111 went in for a chassis change I had the bulkhead replaced as it was easily done as everything was getting stripped. To replace the bulkhead on your tdi would involve a lot of time and work so it makes sense to repair where possible.
    A new bulkhead is ridiculously expensive for what it is. I was lucky I got the series 111 bulkhead at a knock down price from someone who had bought one but his project never got off the ground. The same with the galvanised series 111 chassis I used to replace the old one. The price I paid for the new series 111 galvanised chassis and new bulkhead combined was €1700 or AUD 2,638.74.

  6. #6
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    Maer do a stainless steel bulkhead. Shipping from Poland would not be cheap.

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    Quote Originally Posted by shack View Post
    Others of course may have a different opinion, and you'd need to ascertain the extent, but there wouldn't be many pre 05 defenders without at least that much rust, I'd definitely be fixing it if its only those spots.
    I suppose if it's only these spots I'll probably get it repaired, but I'm assuming it's in more places than just what I can see. The car is currently being inspected professionally, so we'll see. Cheers for the response!

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    Quote Originally Posted by spudfan View Post
    My 200 tdi is 30 years old. There was corrosion in the passenger footwell in the plate facing your toes. This was easily replaced/repaired. The corners of thebulkhead just outside of the windscreen block/hinges was beginning to rust. You can get repair corner pieces or you can just repair the corners. By "you" I mean the garage. Everything else bulkhead wise is solid so that is why these repairs were done. On the other hand when the series 111 went in for a chassis change I had the bulkhead replaced as it was easily done as everything was getting stripped. To replace the bulkhead on your tdi would involve a lot of time and work so it makes sense to repair where possible.
    A new bulkhead is ridiculously expensive for what it is. I was lucky I got the series 111 bulkhead at a knock down price from someone who had bought one but his project never got off the ground. The same with the galvanised series 111 chassis I used to replace the old one. The price I paid for the new series 111 galvanised chassis and new bulkhead combined was €1700 or AUD 2,638.74.
    Yeah I'm finding out what shape the rest of the bulkhead is in - if it's mostly solid repair seems to be the go from the responses I've got so far. I suppose I'm assuming the worst in thinking about a bulkhead replacement, although it'd also be nice to have a fresh gal bulkhead in and then not have to worry about any more rust setting in (for a while anyway)

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    Quote Originally Posted by POD View Post
    Maer do a stainless steel bulkhead. Shipping from Poland would not be cheap.
    A stainless bulkhead would be awesome, although I'm sure very expensive. I'm looking at a Shielder gal bulkhead, which is about $6k AU by the time it get's here from the UK

  10. #10
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    Quote Originally Posted by POD View Post
    Maer do a stainless steel bulkhead.
    Many years ago (about 30), I was running a project to replace a lot of heavily rusted steel, especially bolts, on my employer's site on Norfolk Island.

    I asked the structural engineers about the possibility of using stainless steel bolts to replace the rusted ones. They said definitely not. The galvanic reaction with the steel RSJs would be worse. Better to have the steel bolts corrode than the RSJs.

    A rusty firewall I saw a couple of years back at KLR Automotive. It was a big job to replace it.

    Rusty firewall (1 of 1).jpg
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