Bulkhead-rust-what to do please?

Hi all,

As the rain has pointed out to me that I have a hole in my roof somewhere i decided to investigate the source and came across this little problem!!
Bulkhead rust....Now then, the outside of the vehicle is sound with no signs of rust, so its just on the inside at the moment. The passenger side is ten times worse than the drivers side.
What are my options, shall I Jenolite, paint and forget.....or cut out bad, weld in some sheet to make good and paint?

I have a mig and stick welder, grinder etc but am a bit of a novice to sheet metal work, ive only really welded box section etc for homework jobs in our engineering workshop at work.

Any pointers or pics on what you have done or who you dealt with it etc will be very much appreciated to help me out..

I can then sort out the bloomin roof leak

Im about to have a galvanised bulkhead fitted to mine (along with a galv chassis), but you could always try using some of these...

001 bulkhead repair panels

Hey Lead Farmer, appreciate the response to my posting. I have looked at these repair panels but as I say the outside panel of my bulkhead is sound....its the bit inside - its not needed for any structural reason so i could possibly just treat and paint? Im not sure though....when i come to sell people might not touch it so im after some advice on repairing the inside bit ing any sense? thanks a lot.

joe27979 said:

Hi all,

As the rain has pointed out to me that I have a hole in my roof somewhere i decided to investigate the source and came across this little problem!!
Bulkhead rust....Now then, the outside of the vehicle is sound with no signs of rust, so its just on the inside at the moment. The passenger side is ten times worse than the drivers side.
What are my options, shall I Jenolite, paint and forget.....or cut out bad, weld in some sheet to make good and paint?

I have a mig and stick welder, grinder etc but am a bit of a novice to sheet metal work, ive only really welded box section etc for homework jobs in our engineering workshop at work.

Any pointers or pics on what you have done or who you dealt with it etc will be very much appreciated to help me out..

I can then sort out the bloomin roof leak

Click to expand...

It looks like it can be repaired but it'll require a fair amount of prep and an experienced hand with a welder, a job that will certainly command a few hundred quid at your local stealer. It's essentially the inside skin that has rotten away. You can get hold of repair panels as Leadfarmer suggested but they are really to solve external rot, or rust to the 'outside' skin of the bulkhead as opposed to the inner skin thats rotten away in your case. I think the best plan is to examine the entire bulkhead for any other rot before you start to tackle this problem, because if you do suddenly uncover a lot more that needs attention, it might be in your interest to just swap the whole thing. Give the entire assembly (inside and out) a good whack with a plastic screw driver handle (or the point of a screw driver on areas where paint damage is not important) and listen for 'hollow thuds'. If your screw driver goes straight through... well...

-Pos

-Pos

How difficult is it to replace the bulkhead?

Thanks.

natas said:

How difficult is it to replace the bulkhead?

Thanks.

Click to expand...

um, the question I have is how long for one man to do it in his double garage with no chain blocks etc! )

It's a big job, roof off (or at least wind screen folded down), wings off, wind screen off, floor up, doors off, wiring removed, clutch box removed, steering rack removed and so on and so forth. If I were doing it myself I'd have an angle grinder, a few spare disks and allow myself a week to do it in between other things.

-Pos

I dont have the knowledge, time or space to replace my bulkhead. Which is why Im paying someone to replace it. But the costs soon escalate as it makes sense to replace various other parts whilst your at it.

LeadFarmer - I'm curious who you're having your galv chassis & bulkhead swap done by and if you don't mind, how much they're asking.

Updated pics on rust found so far:
Looks like rest of bulkhead is sound and like new...phew!!

kavefish - Sent you a PM with details

p.s,
This only had an mot 3 months ago when i brought it the owner got his mates garage to do it.

Should it have passed in this state or is this something I should take up with the department of transport?

Many thanks

Hi everyone,
An update on what I have found so far, removed windows and roof to better ascertain the problem, plus its easier to work with them off, I can also seal the leaky roof better )

The rusty bits, whats the easiest weld repair for my door pillars (the rest I can plate and butt weld.....door pillars though - renew or repair patches? thoughts are very welcomed.

joe27979 said:

p.s,
This only had an mot 3 months ago when i brought it the owner got his mates garage to do it.

Should it have passed in this state or is this something I should take up with the department of transport?

Many thanks

Click to expand...

yes most defo - it should not have past in that state.

FFS! AH didn't know how many threads wwere done on this bulkhead:doh: