Thread: Bunyip rebuild

If it warps, you may need to make some kind of frame to bolt it to, then you can use a Gal Solder stick and hot melt that with a gas axe to where it was bolted up.

Originally Posted by bacicat

I'm a bit behind you but I plan on galvanising my bulkhead too. I'm trying to find someone who can dip it to get rid of the rust and paint so I can start the repairs as soon as the patch panels turn up.

If you're talking to galvanisers, let me know how you go - it sounds like some won't touch them.

Not sure if they wrap too much - plenty have been done over the years and I haven't heard too much about warping issues.

I have a local Gal works at Jindera that have done trailers and other small bits for me before. I have the bulkhead in the back of the wagon and will try to get an answer from them tomorrow. The only trouble I can think of is the holes into the various boxed sections may not be large enough to let the pressure out and this can result in burst seams and dangerous liquid explosions in the vats.


I have always drilled large holes in the jobs I have had galvanised that are closed box sections. The worst that can happen is they will knock the job back if they think it is unsafe to do or they will drill extra holes that will need to be patched and plugged.

I dropped the parts and bulkhead at the Gal works today. They decided to have the sandblaster down the road do the bulkhead to get the paint off completely so the chemical dip would work better. He cautioned me about the treaded holes but seemed to think any warping would be ok because the seams where it is spot welded are not too wide and should not cause gas pockets .
I hope to have it back in a week or so then I can start to refit and move forward with the build.
This coming weekend its fit new rear springs and decide what to fit at the rear, fuel tank or winch.

You will need to re-tap all your threaded bolt holes that are there, but its generally a pretty easy job.

We've had a few jobs done through the Jindera guys, they're pretty good. When you go to pick it up, ask them about the Gal Sticks. They just look like a big thick kind of welding rod, I think a triangular shape though.

Originally Posted by Chops

You will need to re-tap all your threaded bolt holes that are there, but its generally a pretty easy job.

We've had a few jobs done through the Jindera guys, they're pretty good. When you go to pick it up, ask them about the Gal Sticks. They just look like a big thick kind of welding rod, I think a triangular shape though.

Thanks Chops I will do that

Looking forward to seeing how it all goes - tell them they may get another one to do. Any idea of cost for all this yet?

Originally Posted by bacicat

Looking forward to seeing how it all goes - tell them they may get another one to do. Any idea of cost for all this yet?

They charge by the Kg and I cannot remember what it was for sure but $2.90 /KG seems to ring a bell and I know the have a minimum charge of $50 for small items that do not add up to the minimum weight of 20kg.
It cost me about $50 for the bulkhead support brackets, battery box, seat box support rails, throttle brackets and rear chassis handles.
I reckon its cheap insurance.

I do not have a clue what the sandblasting will cost but I bet its more than the Gal.

I just got a message that the sandblaster is away till Friday so it will be another week now before its done

Got a call yesterday afternoon to say the work was done so it was around to the Jindera works this morning on my way to another job.
Picked this lot up and started to clean up the threaded holes and dags this evening.
The wife reckons I should leave it unpainted because it looks cool all shine and bling like but I will have to think about it some more first.