90 bulkhead removal (the front one)

Done a couple of searches on this, only seem to find threads on removing the bulkhead behind the seats...

Basically how much of a job is it? Want to pull it out to weld up some rot, then strip back and give it a nice few coats of paint. Im a dab hand with a set of spanners But I need to know whether this will take me days to remove

thanks

outrigger bolts, chassis support bolts, steering column, wiring harnesses, heater matrix pipes, roof, floor plates, tunnel, brake/clutch pipes and that should be about it

If your going that far may as well send it to be galven'd

It's not a particually quick job but one that is certainly worth doing.

I have replaced three bulkheads now (all DIY single handed) and as already stated, it is really just a spanner job but you are disassembling a major part of the vehicle along with all the parts that are bolted to it so don't think you will get it out, welded and ready for painting in a single day.
I had my bulkhead galvanised last year and really recomend it if you intend keeping the vehicle.

The biggest problem is that while it is out you feel the need to do other jobs while you have all that unrestricted access and you have to decide where to draw the line otherwise before you know it you end up with the vehicle completely stripped!

Its at the point where myself and the passenger get wet feet during the rain, not ideal. It'll need a clutch sometime this year, will the bulkhead being out give decent access to the bellhousing?

Tottot, i read sonewhere on here that galv doesn't take unless the chassis is all bare clean metal? While a galv chassis is also on the agenda, its benefitted from a recent rear crossmember and the rest of the chassis seems solid (thankfully) will definatly get another years mot out of it with ease

To take the bulkhead out you will be removing the windscreen, doors, bonnet, front wings & floor. It is a simple task after that to remove the seatbox which means you will have loads of room to remove the gearbox and replace the clutch.

Yes the steel needs to be clean to successfully galvanise so if you suspect there is internal rot then it is not going to be the long-term solution you will be hoping for.
I was lucky in as much as I bought my bulkhead brand-new, looked after it and so when I sent it for galvanising I knew there was no rot, it was cleaned of course (blasting & acid dip) to get it back to bare metal.

So after reading through what needs taking apart a couple of times, its definitely something im capable of, and hope to start the big stripdown after the weekend

Upon refitting the bulkhead, going to fit sound deadening. See if I cant dull out the diesel engine a little bit. As far as the chassis is concerned, theres a couple of holes in the front outriggers, so will cut the patch out and weld a panel in on those. Then possibly paint on that black rust inhibitor stuff (vitrol??) and maybe waxoil over the top.

As for the internal of the chassis...I have vague ideas in motion of somehow filling the chassis rails with waste oil, hopefully stopping any internal rust in its tracks. I have lots of waste oil about the place

will keep rusting away when the oil drips off

Save your pennies for a galv chassis.

Ian46 said:

Save your pennies for a galv chassis.

Click to expand...

What are they retailing for nowadays?

I always thought the reg. of the vehicle went off the vin number stamped on the chassis...so how do people get around this when they purchase replacement chassis'?

I'd like to get my own chassis acid dipped and galv'd if anything, its very tidy at the moment

pbuf said:

What are they retailing for nowadays?

I always thought the reg. of the vehicle went off the vin number stamped on the chassis...so how do people get around this when they purchase replacement chassis'?

I'd like to get my own chassis acid dipped and galv'd if anything, its very tidy at the moment

Click to expand...

i have wondered about this.... i know my front bulkhead is rotting away... and rear crossmember is a gonner amongst a few other bits!

Right then. Progress is occurring! Got the cab off, dash is apart but not yet off, drivers side wing and bonnet is off, also doors and tunnel dismantled.

Struggling to see how to get the passenger side wing off, I cant get access to where it bolts to the bulkhead due to where the air intake thing is in the wing?

Any seasoned pro's feel free to comment

Also can anyone post a quick rundown guide on the dash? taken every screw out I can see yet it still seems attached somewhere...along with the steering column. I thought this would lift out through the dash into the cab but it seems not?

thanks

For my rebuild, I took the air pipe from out of the wing, there may be an easier way. The wings are designed to hook on over the bolts so they only need to be loosened.

Regarding the dashboard, which parts can't you get off?

The plastic tray part of the dash...ive taken the metal inner out but cant seem to get the main partnof the plastic dash to come away from the bulkhead..

Best bet is get a parts manual print off and look for the hidden fittings!

Had a good day today! 10 hours later and finally lifted the bulkhead clear of the rest of the 90. Next job - new clutch and HD release arm to fit.

thanks for all the replies all