Bulkhead mount repair

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Rorie

Active Member
Posts
641
My 1988 Defender 90 has a galv chassis.

Where the bulkhead meets the foot well, its rotted through on both sides (next to and including the door post). Looking underneath, the brackets which mount the bulkhead to the chassis are also in a poor way.

Looking a little further, the sill rail (small channel section running from front to back) is a bit nasty too.

Am I correct in this thinking;
To resolve bulkhead/door pillar; remove floor plate and door to get visibility of bulkhead. If the door post has gone, replace with this
http://www.yrm-metal-solutions.co.uk/epages/BT4822.sf/en_GB/?ObjectPath=/Shops/BT4822/Products/047A

As I know my body mount has gone, I’ll also need to get this
http://www.yrm-metal-solutions.co.uk/epages/BT4822.sf/en_GB/?ObjectPath=/Shops/BT4822/Products/049/SubProducts/049-0001
But does one overlap the other, or do they work in conjunction with each other?
I assume I may need to remove my wing to get proper access to resolve?

For the sill rails, I can get the part noted below. But can anybody advise how this is connected to the car? Is it just nuts and bolts, or are there any welds / rivets?
http://www.yrm-metal-solutions.co.uk/epages/BT4822.sf/en_GB/?ObjectPath=/Shops/BT4822/Products/078/SubProducts/078-0001
How does this interact with the above mentioned parts? I assume it’s a good idea to change all these at the same time, but I’m a little unsure of how they all interact with each other.

Any advice or photos appreciated!
 
Great photos - really helps me understand what i've got in there.... time to get the wing and door off to see what condition its in!

Cheers
 
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