What parts should I buy for a Bulkhead exchange on a defender!

[2234jones]

The Bulkhead on my defender has seen better days and I have just bought a second hand one to repair as its in better shape than mine and requires minor welding and repaint.

I am just requiring advice on what parts I should get in like nuts and bolts and anything that may be needed for the exchange, I also have a brand new wiring loom, as I had a loom fire when I first got it, which will also be fitted .

Thanks in advance Mark

Land Rover 200 Tdi Defender owner (http://landroverfreak.blogspot.com)

[mark2]

I have done a couple of firewall swaps. Off hand, I cant' think of any specific parts you'll need in advance but as you go you may find various clips and plastic plug inserts for self tapping screws which are damaged. Depending on how fussy you are, you may like to replace these.

Suggest you get a box of ziplock sandwich bags and a marker pen and diligently label and categorise all fittings and fasteners in separate bags. Be as methodical as you can, take photos and make particular note of where/how the wiring loom runs and the order in which it comes apart - it can be a bit of a puzzle. There are also various shims for the steering column and firewall support brackets which will need some fiddling to make everything line up.

Consider having the replacement fully sandblasted and primed in an industrial grade epoxy once the welding repairs are done. Another suggestion is to tip the replacement firewall upside down once its painted and get fishoil or lanolin etc to flow downwards into the upper parts of the cavities, before you fit it. I also drill a small hole in each footwell rib cavity and treat with fishoil etc while moving the firewall around to get it flowing everywhere internally.

Its a big job, time consuming and not to be entered into lightly, but very doable if you are systematic about it.

[2234jones]

Thanks for that i have rebuilt a couple of rovers in the past, but they never needed the bulkhead removed, just the rear bodies and wings, and engines. I have also gone through a few magazines I have collected over the years for tips and pointers, may search what parts are involved and may get some new bolts to make re-assembly easier.

thanks again Mark

Land Rover 200 Tdi Defender owner (http://landroverfreak.blogspot.com)

[flagg]

I've been putting this off for months... so I'm keen to see how you go!

(make sure you document it an put i up on AULRO :angel: )

[2234jones]

I picked it up the other day, still sitting in the back of the defender, I bought it from another AULRO forum member for $60-00 who was breaking a 1986 county. It needs minor welding compared to mine and as I stripped it off the chassis I was abled to get some spare bolts and screws and the captive nuts on the new bulkhead look brand new. I had some extra bits given like the steering colum and wiper motor so the first thing will be stripping it down, then fixing the parts to be welded then get it sand blasted before I spray it. I'm allowing a week to do the change as the hard part will be putting it back together as I'm replacing the wiring loom.

just got to plan when I can do it now, as it is a big job.

thanks Mark

Land Rover 200 Tdi Defender owner (http://landroverfreak.blogspot.com)