anyone no how much to replace a bulkhead

i was just wondering how much it would cost me to replace the bulkhead in my 1990 200tdi 90 mine has definatly seen better days, anyone had it done or a mechanic? and how long does it take? :-S cheers jake

decent bulkhead is going to cost you £100 for one that needs work - £300+ for a fully dressed one

2 men 1 days work ish

if you don't DIY add say 20 hours @ £35 ish/h

you do the maths

From me.....

The labour would be about £300-400; plus any sundries (which would include all bolts that will need cutting off etc etc) and of course the cost of the bulkhead itself......which may need work before fitting; no point in putting one on that has rust in it already.

Is it definitely that far beyond repair? To be honest, both footwells, both door pillars and some windscreen surround is going to work out costing similar in terms of labour as well.

send us a pic mate I bet is salvagable. U know you can get the new corner pieces etc. Seriously if you are going to go to all the hassle of swapping a bulkhead you might as well move the whole lot over onto a galv chassis and bulkhead.

Hi,
Just on with the bulkhead myself.
Took two days for me and the wife (she's a good girl) to strip the bulkhead out - ensure you have a hand grinder, impact driver, heat torch and some patience.

As for the replacement:
Ashtrees will do you a galvanised one for £775 with a refund (max £75) for your old one.
defender4x4.com at preston repair them approx £450
You can buy the repair panels from yrm at durham will supply you all the repair panels if you can weld and have a jig!

Ah got a brand new Td5 one on ebay a couple of years back for about £250'ish for my 200Tdi 110. All that was needed to do to it was weld up a couple of holes, drill some holes, stick some nutserts / rivnuts in, cut of the wiper motor bracket, prime, stonechip and paint it, refit the dash and pedal boxes etc.
Ah was lucky that ah had a spare motor sittin' that ah could tart up various bits and pieces in me own time and got a 300tdi steering column and a couple of bits from Sean (cheers mate). All ah really had to buy was the pedal box gaskets, the heater box seal and a load of nuts and bolts. The ironmonger loved me when a turned up wi' loads of wee bags with various nuts and bolts from certain bits! Ah just told him that it keeps me right and ah'll know what bolt fits what and where
Ah've still to do a 'how to' on removing the bulkhead yet, but most of the various other bits and pieces are in me guides.

You were lucky!

How long to put it all back together?

bluehaze said:

You were lucky!

How long to put it all back together?

Click to expand...

Ah think it was about a weekends work. Had to get a mate to help lift the old one out and new one in but ah stripped the stuff and rebuilt it again mesel'.... and that was the furst time

Jake, any joy?

Tis a slow boring job doing all the usual bits on a bulkhead. Started mine in the summer and spent a good few hours (days!) on it.

Most time consuming is drilling out all the hundreds of spot welds.

This'll give you an idea:
bulkhead rebuild pics

I'd be wary of putting in a 2nd hand one as they rot from the inside out so even if you can't see any rot........

Do a search for posts by me, I did a massive post about a year ago on how to do it and what was needed, there was then a lot of info added to it by other people who had done a bulkhead. It became quite a useful posting - might be worth bringing it near the top again.

Are there any differences between 200 tdi, 300 tdi, td5 and puma bulkheads?

John cradocks is selling air conditioned ones (not bothered about the flaps) for £534

Is it worth getting a galvanised one?

New td5 bulkhead £250 - absolute bargain
Just need to alter a thing two

im still thinking about which way to go with it, im a welder by trade so i should do the repairs myself and i could probs make up the repair panels myself at work, i was just trying to do the lazy option :-S

jake04551525 said:

im still thinking about which way to go with it, im a welder by trade so i should do the repairs myself and i could probs make up the repair panels myself at work, i was just trying to do the lazy option :-S

Click to expand...

a mate runs a body repair shop when i was around for him to do my quote for the insurance he said the labour time for a bulkhead replacement in his book is 28 hours

wow that does not sound too good i think i will have a bash at doing it myself, t will definatly be cheaper but i think i will buy the repair panels to save me the hastle of making them, i spose that way i dont have to strip the thing apart as much..

Jake,

Maybe a big far for you but check this out......Landrover Land Rover bulkhead Defender / Series on eBay (end time 20-Dec-09 19:56:08 GMT)

Mine is 21yrs old so a few of the fixings were a bit worse for wear - total man hours for removal was 17hrs. Then spent (this morning) 3hrs stripping the td5 one. Having done the measurements and analysis it only needs a hole for the electrics and two rivnuts for the fuel filter fitting. once the weather gets back to normal the new bulkhead can be rubbed down and resprayed before being refitted.

In reality this is a real ball***e but the results should good.

If you're after a smaller time frame then consider buying another, sorting it out then swapping them over?