Bulkhead Advice please

Hi, im a landrover virgin (awaiting Haynes manuals to be delivered!)
I have a few 'Holes' in the bulkhead, I know it adds character but I want to patch them until I can get a Galvanised one fitted (after it's next MOT hopefully)

Pic one is of the passenger side foot well, will this be able to be cut out and riveted in or is it too far gone?


Pic two is from the engine bay by the brake servo cylinder thingy (excuse my lack of knowledge but the manuals are in the post) I have a friend who can weld/fabricate, will this be a possible fix?



Thanks in advance for any answers

Anything is possible to fix with the right amount of time + funds i guess..

The repair panels can be brought from YRM metal solutions. just put that into google and you'll find it.

What are the corners like under the wind screen?

yabba dabba doo

To be honest, it is looking like it might need quite a bit of work. I'd want to go all over it with a little hammer or something similar and see where else it is deteriorating. Previous owners may just have buttered a bit of filler into holes, so it's important to appreciate the full horror of the situation before deciding whether to repair or replace.

There are a few people on here who have done wonders with rusted out bulkheads that I'd have thrown away, so with perseverance anything is possible.

Hi,
Plenty of manuals available online if you search about.
Footwell looks well on the way and I would plan to replace with footwell repair panel. I will guess that there will be more rust appear as you delve in to make any repairs especially on the bulkhead itself.....(if it's anything like mine was).

Footwell isn't too bad a job, the bulkhead can get tricky and it be necessary to conjure up some pieces of steel for welding as not everything is available as repair panels.

Thanks for the replies, The drivers corner under the windscreen has surface rust and the passenger side has already been swapped and primed (doesn't feel like There's any filler under it.)
I've ordered the replacement foot well (forgot to order new floor bolts doh!)
And I'll have a go this weekend.
I only want the repairs to last about a year /year and a half max as I intend to get a galvanised bulkhead as the chassis is galvanised.
The only thing that concerns me is the metal to the right of the footwell as it looks to be part of the bulkhead that the footwell will rivet onto.

Thanks for the Haynes manual holder bag idea


Cheers

Dont want to be the bearer of bad news, but waiting till it's next MOT may not be possible. The second photo shows some quite crusty metal near the brake master cylinder (the surrounding 30cm of the brake master cylinder, plus other key parts has to be solid. ) It may well fail on that (and perhaps should have failed on its current MOT), so I'd keep that in mind whilst planning next steps.

Edit: Sorry, you're wanting to do it properly after next MOT, this is to tide you over.

I had pretty much same rot near master cylinder done, just cut it out and created template out of cardboard for gap, cut it out of metal and welded in. Job done

Before now I have used fibre glass to " get by " on chassis / inner wings and bulkheads obviously it has no structural rigidity but if it's just holes and you're limited on time ......

lurch915 said:

Before now I have used fibre glass to " get by " on chassis / inner wings and bulkheads obviously it has no structural rigidity but if it's just holes and you're limited on time ......

Click to expand...

Nooooooooooooooooooooooooooo! :violent:

+1 on the Noooooooooooooooo

That bulkhead looks in very poor condition and you will undoubtedly find a lot more when you start stripping it down. If you are going to all that trouble it might be worth going for a straight swap. Galv ones are approx £900

Only to get by I've seen worse go for mot's , the duck tape and body filler is a classic !

I'm not in a big rush the next MOT is 8 months but it will be my only vehicle soon for weekend use. So I want it to be sound and safe.

I was thinking of grinding out the rotten foot well with the bulkhead in place. Then riveting the YRM part on then sealing with PU40 (bad idea?)

The truck is a keeper so will be done properly and have a replacement bulkhead, just trying to extend the life of this one a little without doing damage to anything else in the process, including my pocket!

will it damage anything else or is it unsafe to use it as it is?

I work with computers and am learning as i go, I have a few friends who have mehcanical/engineering skills but want to do as much as possible on my own and only call in favours when really necessary.

Thanks for the input so far

The repair panels should be welded in.

Have you had a poke/hammer about on the door post? (The rectangular post fixed to the side of the floor pan) This will give you a good idea of how far the corrosion has gone.

Looking at the corrosion in the floor pan I would be surprised if the door post is still solid. They usually start at the bottom and work their way up. Tin worm works in mysterious ways though and they may be ok

The bulkhead is fixed to the chassis with two big bolts, one through the bottom of each door post and some smaller fixings at the top of the floor pan. This makes these sections very important as your steering wheel, brake pedal/servo, clutch pedal etc are fixed to it. Not to mention the front of the roof via the windscreen frame.