Fitting Bulkhead

[SwampyWales]

Hi

I have a Defender 90 which I removed the front bulkhead from to repair. I am now attempting to refit it!

Can anyone tell me how to do this!!! I cannot get the bulkhead in as the lugs on the "feet" catch the sills. I have measure these lugs and they are very, very similar in size to the original ones but for the life of me, I cannot get the bulkhead in.

It doesn't matter if I tilt it, or put it on straight, I cant get it past the sills.

Is there a trick to doing this? I really dont want to take the sills off - there must be a way?

Many thanks

 

[Turboman]

Hi

I have a Defender 90 which I removed the front bulkhead from to repair. I am now attempting to refit it!

Can anyone tell me how to do this!!! I cannot get the bulkhead in as the lugs on the "feet" catch the sills. I have measure these lugs and they are very, very similar in size to the original ones but for the life of me, I cannot get the bulkhead in.

It doesn't matter if I tilt it, or put it on straight, I cant get it past the sills.

Is there a trick to doing this? I really dont want to take the sills off - there must be a way?

Many thanks

Could you clarify exactly what you mean by "front bulkhead"?

 

[SwampyWales]

Could you clarify exactly what you mean by "front bulkhead"?

Sorry - I mean the main bulkhead. The one the steering column goes through and that had the pedals attached

 

[Turboman]

Sorry - I mean the main bulkhead. The one the steering column goes through and that had the pedals attached

Thanks. And by "sills", do you mean the little alloy strips that bolt along under the doors at the sides of the vehicle?

 

[SwampyWales]

Thanks. And by "sills", do you mean the little alloy strips that bolt along under the doors at the sides of the vehicle?

Hopefully the attached image will explain. The red arrow shows where the bulkhead needs to go!!

 

[Turboman]

Hopefully the attached image will explain. The red arrow shows where the bulkhead needs to go!!

I am not absolutely certain, but it looks to me like you may have some kind of rock slider fitted, and there is certainly some chequer plate present.
But I can't see that either would interfere with the tube in the base of the door pillar going down into the gap.

Are you sure that everything is the same as when you removed it? I notice the outrigger looks very clean? Has that been replaced while the bulkhead has been out? Or have you replaced the bottom section of the door pillar on the bulkhead?

 

[jamesmartin]

Hopefully the attached image will explain. The red arrow shows where the bulkhead needs to go!!

you need to fit bulk head first then the sill bolts to it

 

[Turboman]

you need to fit bulk head first then the sill bolts to it

That is what I have always done. But he says he doesn't want to. I assume the sill has been welded on further back.

 

[jamesmartin]

That is what I have always done. But he says he doesn't want to. I assume the sill has been welded on further back.

theres no other choice without moving the outrigger

 

[Turboman]

theres no other choice without moving the outrigger

He may have done that already. It looks very clean in his pic.

 

[SwampyWales]

outrigger has been replaced yes.

it was a bugger to get the bulkhead out! Maybe I should have removed the sill to do that??? It is a simple job to remove the sills? Any advice gratefully received!

 

[Turboman]

outrigger has been replaced yes.

it was a bugger to get the bulkhead out! Maybe I should have removed the sill to do that??? It is a simple job to remove the sills? Any advice gratefully received!

It is usual to remove the sills, then the bulkhead, and then replace the bulkhead, followed by the sills.
If the sills are standard, it is a simple unbolting job. But these vehicles have often been cut about quite a bit over the years.
If you have replaced the outrigger, it is unlikely to be in exactly the same place, and maybe not exactly the same size.
So probably best to take off the sills, and re-assemble in the usual way.

 

[brianp38dse]

Hello and welcome

 

[Hippo]

Welcome to the forum