bulkhead replacement

hi, i'm new here and was hoping someone out there could give me some advice. i just bought myself a 110 hardtop 1992 200 tdi.it has spent all its life on a farm and was being used as a dog kennel.its only done 45k but it looks like it has ploughed fields for most of that time.i found 1 panel without a scratch or dint. the dogs ate the seats, but it passed the mot, just needed all new bushes, track rod ends, steering drop arm etc, chassis is solid an it only cost me 150 quid so i am fairly happy. big problem is that the bulkhead is rotten, it seems ok under the bonnet but under dash near the pedals you can push your fingers through it. is it a major job to repalce repair it? and what is involved doing it? has anybody done theirs, an what is it likely to cost me? any advice would be greatly appreciated folks

have just replaced mine on my 91 defender. bought a good bulkhead for 250quid then paid 100quid too have it galvanised, not a quick and easy job.

what do you think agarage would charge to fit one?

dont take it to a garage. with a bag of spanners (and a socket set) some copper grease, it is easy to do yourself.

get a replacement bulkhead,
disconnect battery
remove wings, bonnet, and grill,
remove front doors,
floor and tranny tunnel,
remove windscreen
unbolt sill lower panel and the bar behind them (do not know the propper name, but you will see it.
disconnect the cables going to/ from the bulkhead after taking note of what goes where!
safely remove clutch & brake servo lines
once bulkhead is fully disconnected, unbolt the two big bolts, remove bulkhead.
now transfer any wiires fixings etc and reverse the above, be sure to bleed the break and clutch before road use,

i did mine in about two days with my brother, we took our time outside in the winter, the bulkhead was from a petrol mine is a 2.5 td so all wires etc had to be transfered, in the summertime if you start first thing you could have it done in a day!
i have a few basic pics of mine if you want, i could try to send some to you. but it is not a hard job, maybe a bit awkward finding all the fixings and cutting the inevitable siezed ones.

Great info, taffi

please bear in mind there are a few more steps. but i did not want to insult your intelligence by saying undo this bolt then stop for a brew, pick up spanner have more brew lol
if you were in dubai i would offer i pop round to help. lol

hi taffi_jj
can you please send me any pics and tips since iam on the way to change my bulkhead
regards

have a look in me guides and ye'll find some stuff in there that might be handy. And if ye try doin' a search on here ye might even find some photies of when ah did mine

Where are you at?

bluehaze said:

Where are you at?

Click to expand...

Ah'm at home in front of the computer havin' several beers