Bulkhead Problems!!!

Good Evening Guys!

While washing the lime dust off of my 90, I found that the questionable areas above the vents have actually flaked a bit more than I had thought. So while prodding around I've so far come across two pin prick holes.
Now I know that I've got to get the rest of the flaked paint off and survey the situation fully and decided to patch or start thinking bigger!

But my problem is, the MOT is due this week and I don't particularly want to take her off the road. Bellow Ive (hopefully) stuck a couple of pictures in, I would love for some advice, Is there any hope in hell it will pass as is and if not what would you recommend I do???

My truck came with about 10 months MOT and a hidden tub of filler, so i guess you could fill it and paint to get it through and then address it later, you'll probably find a whole lot more once you take it apart to fix it though.

2x1 timber fits in nicely,ask me how I know lol.

So, the reason it will fail are :

Corrosion within 30 cm of brake master cylinder

Corrosion within 30cm of some other item that needs to be held down (steering mounts, .....likely others that I can't think of).

If it's within 30cm of any items like that, it will (should) fail.

You could try and fill it (and also would need to paint to disguise the filler), however you should ask yourself what that will achieve.....if it is due to fail, it means that it's dangerous.

If you were filling to get through, to then take off the road and repair, fair enough.

You need to have a look around, if it's rotten there there's a chance it may be bad else where. Common areas are under the bonnet on the "bar" going across where there's some stickers, the brake master cylinder bolts to, the steering shaft bolts to etc.

I'd try and find some time where it can be off the road, to get it done. Either by yourself or getting someone in...

Pffff, This is true!

I'm not sure if the holes are within 30cm or not, which point do you measure from exactly?

My current plan is to get a couple of opinions and get it in at the garage at work so I can have a good look around it, plus there it is in a place to get the work done! I have found a touch more corrosion next to the Brake Master Cylinder which has sealed the deal I think!
The corrosion along the top is isolated from what I can see, I have taken the flaked paint off and gone down the metal and taped around with a screw driver and it looks to be from the outside in so I think I could patch this with some new steel. The other corrosion I am not yet sure about until I've had someone else take a look.

Derby7889 said:

Pffff, This is true!

I'm not sure if the holes are within 30cm or not, which point do you measure from exactly?

Click to expand...

I'm not sure, but I'd get a ruler and measure from the corrosion nearest to brake master cylinder/other parts that are secured and important.

At the end of the day, the MOT guy's opinion is what matters....

If the corrosion is between the m/cyl mount where its bolts to the bulkhead between it and the wing its quite common, mine had failed into a small hole on the weld seam, small bit of alloy and 4 pop rivets later its been fine ever since!
They also go the other side under where the heater bolts to the bulkhead.

wait until you get it shot blasted
mine had small holes behind the dash and a small hole in the footwell
but when it was blasted, it looked like swiss cheese