Thread: Design Feature that Causes Rust to Bulkheads - How to Upgrade?

The problem is any box section or double skinned section is difficult to treat against rust.
It could be condensation forming on the inside, water getting in from top (or bottom) or water not getting out.
The windscreen seal as it decays would allow water to sit between frame & bulkhead, the vent seals could trap water as they come unstuck or break down.

On door frames & door tops I seal all but one hole, tip some paint inside the frame & roll around to ensure coverage & then drain. I hope this will hold the rust back.

'A' pillar and around the vents would be the fact that its boxed in. Once the rust is cut out and the repairs made you should get some paint and/or fish oil (or similar cavity wax) into all the enclosed sections.
Floor panels take a lot of stone damage and are sprayed with water when it rains so maybe an rubberised underseal to protect them. Sometimes underseal can hide rust so maybe a decent coat of paint and regular checks & touch ups is a better alternative for floor panels.

All of mine have been OK with just some minor rust damage. Maybe they were garaged ? I have a bulkhead from a '55 Series I that came from a car that sat in a field for about 20 years, the only rust is in one small double skinned section.


Colin

The other thing you can do to minimise rust in the bulkhead is to move inland, and preferably further south!

Otherwise, pretty much as Colin says, but I would add a couple of points. Keep the vehicle under cover as much as possible, and use it regularly - the engine heat will dry out the bulkhead to a significant extent.

And hose the mud off and avoid beach work.

Originally Posted by JDNSW

The other thing you can do to minimise rust in the bulkhead is to move inland, and preferably further south!

Otherwise, pretty much as Colin says, but I would add a couple of points. Keep the vehicle under cover as much as possible, and use it regularly - the engine heat will dry out the bulkhead to a significant extent.

And hose the mud off and avoid beach work.

Hello John,

Yes, the sub tropical status of Bundaberg, and its coastal location is a contributing factor to corrosion. Well not so much in the way of rain over the past months. The soil is dry and cracking. The main ground cover colour is brown at the moment and it crackles when walked over.

Then again, the grass does not need mowing every fortnight like it will during the peak of summer here. It would be nice to see the place green again though.

Kind regards
Lionel