Bhudda's 200Tdi Chassis Swap

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Well just back from MOT test and.....................
IMG_8810.JPG


Passed no advisories the tester said its best one he's seen and was quite disappointed he usually badgers me to sell it but said today 'pointless even asking if you're selling after all the work you've done':D
 
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Disco1BFG said:
Clean ticket is a great result :) - Well done - I hope you are proud of that, I know I would be!
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Yeah it is a great result I asked Duncan the tester to go through it with a fine tooth comb! He got his brother Robert to test it as he hates older motors but even he couldn't find fault said it's the best one he's ever seen underneath everything as it should be. So I'm well chuffed it's good to get bit recognition from the pros :D:D:D
 
TorsionBhudda said:
Yeah it is a great result I asked Duncan the tester to go through it with a fine tooth comb! He got his brother Robert to test it as he hates older motors but even he couldn't find fault said it's the best one he's ever seen underneath everything as it should be. So I'm well chuffed it's good to get bit recognition from the pros :D:D:D
Click to expand...
Awesome achievement, marra! :) Absolutely crackin job. :cool:
Just looking at this picture.
IMG_8638.JPG

As you're talking about the door fitment I presume the bulkhead bolts are tightened down? It looks like a big gap to me. I'm going to look through my pictures to see if I can find a similar one of mine to compare.
EDIT
Had the wrong picture there before, so just changed it.
 
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I'll look for another one, but this one might be worth a look at.
Do you think the bottom of your door posts could be welded on the wrong way around?
IMG_5454.JPG

If you zoom in on the bottom of mine the 'tube' the bolt comes through projects in to the door cavity, whereas yours is between the bulkhead and the outrigger. You probably know this but, if you right click on the image and select Open image in new tab, you will get a stand alone version of the image. Press and hold down the CTRL button and then press the + button and the image gets bigger each time you press the + You'll need to press CTRL and - to get the browser to go back to it's usual size.
 
Al2O3 said:
Awesome achievement, marra! :) Absolutely crackin job. :cool:

Just looking at this picture. As you're talking about the door fitment I presume the bulkhead bolts are tightened down? It looks like a big gap to me. I'm going to look through my pictures to see if I can find a similar o ne of mine to compare.
Click to expand...

That door gap closed up once everything was tightened down and roof fitted it's about 3-4mm now.
Problem is the passenger side the gap at windscreen is slightly big but seals ok and doesn't let water in but at the tubside it over laps the side panel and I can't physically get the door to go forward anymore. View attachment 137298 View attachment 137299 View attachment 137300
Al2O3 said:
I'll look for another one, but this one might be worth a look at.
Do you think the bottom of your door posts could be welded on the wrong way around?
View attachment 137301
If you zoom in on the bottom of mine the 'tube' the bolt comes through projects in to the door cavity, whereas yours is between the bulkhead and the outrigger. You probably know this but, if you right click on the image and select Open image in new tab, you will get a stand alone version of the image. Press and hold down the CTRL button and then press the + button and the image gets bigger each time you press the + You'll need to press CTRL and - to get the browser to go back to it's usual size.
Click to expand...

Hi Al
Yours looks different to mines I have that little 'tube' on both sides of the door pillars :confused: Now you've got me thinking. That would explain the issue in having like I've said before I'm considering cutting down the tube on passenger side
 
Hold on, mate. The angle of that picture I posted above is deceiving. I've been looking for more.
EDIT
Is it just me or is the website on the blink? I'm tring to add another picture but, it's saying the server can't process it.
My bulkhead also has a tube on either side. I'll post the picture when it lets me.
 
Al2O3 said:
Hold on, mate. The angle of that picture I posted above is deceiving. I've been looking for more.
EDIT
Is it just me or is the website on the blink? I'm tring to add another picture but, it's saying the server can't process it.
My bulkhead also has a tube on either side. I'll post the picture when it lets me.
Click to expand...
No problem mate yeah it does seem slow tonight I was getting error messages when trying to post I just thought it was because I'm posting from my phone
 
Al2O3 said:
I'll look for another one, but this one might be worth a look at.
Do you think the bottom of your door posts could be welded on the wrong way around?
View attachment 137301
If you zoom in on the bottom of mine the 'tube' the bolt comes through projects in to the door cavity, whereas yours is between the bulkhead and the outrigger. You probably know this but, if you right click on the image and select Open image in new tab, you will get a stand alone version of the image. Press and hold down the CTRL button and then press the + button and the image gets bigger each time you press the + You'll need to press CTRL and - to get the browser to go back to it's usual size.
Click to expand...
My one is the same as the other one, i also used some washers in between to adjust the left a bit as it was a bit twisted sitting on the broken chassis but ratchet straps bent mine into shape. Roof gap on one side was bigger, the same as the other one and sealant was used as well.
 
Al2O3 said:
View attachment 137302
View attachment 137303
The angles change the perspective quite a bit.
Your tube does look quite long though. (Ooh, matron ;))
Click to expand...

It might be bulkhead is slightly warped after it got galvanised I'm just going to cut the tube down a bit see how it goes if I cut too much out I can always add a washer back in. Have to wait till after the silly season is over and I've got enough brownie points from the girlfriend (she was more relieved than me it passed) before I tackle it.
 
TorsionBhudda said:
It might be bulkhead is slightly warped after it got galvanised I'm just going to cut the tube down a bit see how it goes if I cut too much out I can always add a washer back in. Have to wait till after the silly season is over and I've got enough brownie points from the girlfriend (she was more relieved than me it passed) before I tackle it.
Click to expand...
Just been looking back through your pictures again. The main issue seems to be the top of the passenger door? Is that right?
I would be cutting the galvanised bulkhead as a last resort! Maybe that's just me :(
I would be looking at the bracket from the chassis rail to the back of the footwell on the passenger side. I reckon you will need to loosen everything off though, in order to give you the wriggle room to get the shut line and line stuff up. (probably including the roof bolts)
Again, it could be the angle of the picture, but there's one of yours that shows the join between the screen frame and bulkhead. The screen frame looks as though it's tilted back, which will reduce the gap for the top of the door to fit in. I found that a small movement of one panel or body part, give a surprising amount of movement elsewhere. I reckon it just needs a bit more jiggling around. :)
 
Yeah I'll try moving everything about first when I loosen it all off. The other issue that makes me think cutting the tube first is the front panel that the grill screws too isn't square passenger side almost touches full size intercooler where as drivers side has plenty clearance and the passenger wing sits further back than drivers side when I measure to center of bumper bolt holes. I have a pic but it won't let me upload keeps saying it's too large pfft
 
TorsionBhudda said:
Yeah I'll try moving everything about first when I loosen it all off. The other issue that makes me think cutting the tube first is the front panel that the grill screws too isn't square passenger side almost touches full size intercooler where as drivers side has plenty clearance and the passenger wing sits further back than drivers side when I measure to center of bumper bolt holes. I have a pic but it won't let me upload keeps saying it's too large pfft
Click to expand...
Yeah, it wouldn't let me upload pictures either saying they were too large.
If you loosen everything, adjust it and see if you can get the chassis rail bracket to pull the bulkhead forward 5mm. That'll also push the wing forward, which will push the rad surround forward that the grill screws in to. Move it off the intercooler on that side too.
 
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