Thread: Bulkhead/firewall/cowl replacement - is it worth it, how much of a PITA on an RRC?

Apart from the fact nearly everything needs to be pulled off the firewall, is this a seriously huge PITA issue to replace?

I have just discovered that the body-sealant on the top of the firewall where the cowl joins it is hiding rust - almost along the entire length.

Before I tackle this issue, I'm wondering if it is worth purchasing a complete 'bulkhead' as the poms call it, or if I fab up some stainless sheet infill sections and tig it.

I realize this could also be a complete waste of time, and that complete 4 door bodies could possibly be purchased for less money.... BUT time..... ohh time.

Ideally, this can be tackled at the exact same time the OM606 goes in, as the body needs to come off the chassis so it can be done efficiently.


If anyone has some good suggestions about tackling the bodywork or has experience with the rust in this area (pretty sure it's a common RRC rust area) please let me know.

Bodywork is not something I have tremendous patience for....

Originally Posted by 86mud

Do you have the 4x4 is born DVD? This DVD shows you how to pull off the front section including the firewall. Everything needs to removed off the panels, but you may have no choice if the rust is that bad

No, I don't have that - but I think some years ago I watched it on youtube - each episode - thing is as I remember, it was a defender 90 onto an RRC chassis?

I'm reasonably aware that most of the front end will have to come off - it will have to anyway when the OM606 goes in, even then, we're most likely going to separate the body from the chassis to do much of the work. the thing that I wanted to "make sure of" was that there's someone who's either a) replaced the cowl section before; b) replaced the upper firewall section; c) perhaps restored this section with complete pressings, rather than a patch - and if that was advantageous or a waste of time.

The way it stands, the sealant join along the top of the firewall in the engine bay has let out at the top, showing the rust on the seam. For now, I've done the "phosphoric acid" method on that rust. I know this is not a permanent cure, and because of where it is, I'm thinking - hmmm new cowl - probably a good idea, new firewall? maybe if it's not stupidly expensive...

Given that you can replace an entire RRC front end sheet metal with a complete prefab unit complete with stainless fasteners for about 1700 bucks, I was wondering if anyone had a source for the cowl or firewall... if not, then the wrecker will be my destination I guess.

If I had enough time, I would undertake this myself. but I don't have the space at the moment and I also do not have the time - so that means I have to pay someone who may not be as 'fussy' as I am to do the work.

I'd even pull the whole front off if it meant getting it done "quicker" but since I have literally zero space right now, I'm pretty much screwed.

I can see now why people just park these things up and leave them to rot.