bulkhead replacemenet,, what parts will i need

hi everyone.. my bulkhead is currently away been galvanised and should be back in a few days.. im just wondering what i will need when replacing it.. i havent removed the old one yet and ive never done one before so im not sure what will need replacing.. obviously i will need new vent seals but what else will i need.. i would appreciate any info anyone has,, as i dont want to be ordering parts every few days when i realise i need x y or z

Seal under the screen and the foam seal for the heater box to start.

New plastic inserts where the screws go(forget what they are called) if you can't rescue them complete off your old one.
I had to replace most of the rivnuts on mine as the threads got knacked with galv.
Lots of paintable seam sealer to go round every panel join.
New gaskets for pedal boxes(easy to make from cork or something)
Check your threads before painting!!
You may find the flap hinge tubes are blocked with galv too, check before painting!!!
Make sure the large bulk head bolts ,bottom of Piller to outriggers, will slip through ok..mine needed galv cleaning out of them as well.
Check before painting!!!!

Did you remove the mesh behind the vents, if not these will most likely be filled in making the vents redundant.
I removed mine (only a few small welds to grind away) and bonded them back into place afterwards.

Agreed that the flap hinge-tubes will almost certainly be filled, I started drilling mine out then found that I could tap a long thin rod through the galv and this cleared it completely with no damage.

With regards to the hols where the plastic inserts fit, some of these will be almost invisible when you get the bulkhead back and most / all will need to be cleaned out (if you can find them).
Before I sent my bulkhead off I photographed it from every angle plus made a note & measurement of each hole / thread so that when it came back I knew where I should find them. Worked exceedingly well and I am so glad I did it.

a set of small files to square off the insert holes baCK to the right square shape, and the right size.

and be prepared for everything to need adjusting with either a file, hammer, grinder or more !

The biggest challenge for me was to enable the captive nuts for the front door to slide in. The galv had snotted into lumps on the backside and it was impossible to remove due to virtually no access.

cheers everyone.. i put bolts in the threaded holes before having it galvanised so i will heat it up before removing it.. hopefully it goes well..
i never thought of all those little inserts for the screws..
think i will just buy new ones as i will never get them all back out of the old bulkhead without damaging a few i think..
i was thinking of using tech 7 or similar to seal around the brake pedals and those kind of areas..
thanks for all the tips on cleaning out holes and for removing galvanise in hard to reach places.. it seems this will be trickier than i thought to do lol

I put bolts back into my threads and some of them wouldn't come out again even with heat, the rivnuts just turned instead rendering them useless!
Take the bolts out and retap them after?
Luckily I've got a pro rivnuts gun so it wasn't a major issue. I had to replace the steering column and the fuel filter ones. You must use steel inserts for the column ones not aluminium because it's a safety issue.

Don't be surprised if you have to cut the old bulkhead to chassis bolts. You can buy stainless replacements. Have a look at the YRM site - they sell some of the bits you will need to complete the change.

David, if you look at the top of the page, a sticky called part numbers and paint colours. Scroll down to baulkhead and it will show all rubbers, grommets and everything else needed and their part numbers.

David, I am looking at replacing my bulkhead too, where did you send it to be repaired and galv’d? How much did it cost?

Shane512 said:

David, I am looking at replacing my bulkhead too, where did you send it to be repaired and galv’d? How much did it cost?

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hi shane i left it into sperrin galavising in tynagh http://sperringalvanisers.com/ .. will hopefully get time to collect it tomorrow and i will let you know how much it costs.. i had it sand blasted and i repaired it myself.. im in ireland so that company i mentioned will be of no use to you unless the have a uk depot somewhere

mick the builder said:

David, if you look at the top of the page, a sticky called part numbers and paint colours. Scroll down to baulkhead and it will show all rubbers, grommets and everything else needed and their part numbers.

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Evening, Mick. Are you referring to the link below. I can't see a post in that thread that just refers to the buklkhead.

Page 826 of the Body & Chassis Link

http://www.retroanaconda.com/landrover/parts_books/110/9_body_and_chassis_p741-909.pdf

I've not posted the numbers, as some parts are vin specific

Evening Al ,Page 750 to 753. Is the diagrams I'm referring to. I didn't realise they were vin specific.

mick the builder said:

Evening Al ,Page 750 to 753. Is the diagrams I'm referring to. I didn't realise they were vin specific.

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Ok, cheers.

picked the bulkhead up earlier and it cost 56 euro to galvanise.. however in the process of galvaising it they have bent part of the bulkhead up at the air vent.. looks like it got a slap of something.. they have offered to regalvanise it for free once i get it straightened.. lets hope that i can.. will post a picture of it later when i wrestle it out of the back of the car

Good price but bad handling.