Thread: Steel for firewall repairs

If you have a signifigant amount of welding to do a mig or gas less mig makes the day go a bit quicker. New bulk heads can be bought from the uk look in land rover monthly mags ect. Postage for that size will be a killer, make it worth while either was and rust proof everything.
best of luck mate.

I use 1mm cold-rolled steel for my rust repairs.

It is easy to form and beat,

Cheers Charlie

I don't need a whole new bulkhead - there's just a some good sized holes. I'll see if I can get some of the 1mm stuff, unless anyone has any other suggestions.

Check out ebay or the usual - paddocks etc.. they have most of the bits ready made.. and that will save you a HEAP of time.

like this:

Land Rover Defender | Doors | Sill Panels | Door Cards | Paddock

Also, who ever does the welding for you will love that all the parts (more or less) fit.

Shame you are not in Canberra, or I'd give you a hand.

Where abouts in brissy are you located?
Any chance you can get some pics of the rust?
And second on the pre folded panels, the worst part of welding is trying to make a panel that has all the right curves and folds and gives a nice butt joint.
It sounds like we have similar rust problems.

I'm in Arana Hills on the northside. I think this is a common problem. There was a small hole near the top corner of the bulkhead but the rust has spread lower down. Mine is not terminal, just painful

Originally Posted by Dave_S

There was a small hole near the top corner of the bulkhead but the rust has spread lower down. Mine is not terminal, just painful

Yeah - that's how mine started. I think it was due to the poor sealing of the firewall / windscreen panel. The problem is that it will be rusting from the inside out. I found that while it looked good for the most part, a lot more than I originally expected was too far gone. Before you weld it up, make sure you get the whole of the inside of it with rust converter.

I just did this 'best efforts' for what I could see.. and I'm now having to replace the whole firewall, which I can assure you is a Royal pain in the backside.

I don't think I'll have to replace the whole firewall, at least not for a long time. I guess that would take a bit more than an afternoon

I had a look at the replacement panels, but unfortunately I would still have to fabricate some of the metal they attach to. I reckon I'll try to figure out a simple series of patches that can be seam welded in sequence. It shouldn't be too hard or look too bad, at least in theory.

I plan to use rust converter where possible and then pretty much fill up the A pillar and any other accessible box section with some sort of rust protection. Any suggestions there? The UK "waxoyl" products don't seem to be available here.