Bulkhead swap 300TDi Defender

Hi Guys,
Having just completed the resto of an 86", next in the queue is replacement of the Defender bulkhead and got a warm-climate rust free one ready to paint.
Question is, whether to have a go at it myself or farm out the job? Anyone any idea of the hours / pitfalls for a reasonably competent amateur, or the hours for a Landie specialist who's done them before?
Thanks,
Anthony

Do it yourself (you will need another person for a few jobs)

Remove roof & windscreen(2person possible 3)
Remove doors
Remove wings/bonnet/radiator slam panel
Remove floor/tunnel
Remove all items off old bulkhead
Remove bulkhead(2person)
Instal new bulkhead
Refit all items
Refit doors
Refit roof/windscreen
Shim bulkhead for gaps
Refit wings
Allow for replacement bolts for wings,door hinge & fixings
60hrs if your good with spanners

(I done this between other jobs & had my forklift for heavy lifting)

Many thanks for that, Phill. Mmm, 60 hours - that's I suppose a solid week and probably more, and of course you'll probably find some "whilst I'm at it" jobs too. I might see if I can come up with someone who can do it at a decent rate, rather than a garage charging £45 or so + VAT per hour, otherwise it will be £3000 or so - and thus I'll end up doing it myself !

Superaquarama said:

Many thanks for that, Phill. Mmm, 60 hours - that's I suppose a solid week and probably more, and of course you'll probably find some "whilst I'm at it" jobs too. I might see if I can come up with someone who can do it at a decent rate, rather than a garage charging £45 or so + VAT per hour, otherwise it will be £3000 or so - and thus I'll end up doing it myself !

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They will find all the other jobs and charge you for every new nut & bolt. They won’t try to remove these.

Do it yourself for satisfaction & experience.

Before you do all this work, what is the chassis like?

Sorry forgot to ask , What part of the world are you? People may know some locals who do this work

Yes, you're probably right ! We're on the Wales - Shropshire border, near Montgomery. Galvanised chassis.

Superaquarama said:

Yes, you're probably right ! We're on the Wales - Shropshire border, near Montgomery. Galvanised chassis.

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Well worth a good bulkhead then.

Another vote for do it yourself. If you work at is solidly it can be done in a weekend. I know it is a little simpler but I did my series bulkhead in 2.5 days (long days, maybe 32 hours ish) working on my own. I did it over an easter bank holiday so I had four days to do the job, started Thursday evening and drove it out the barn Saturday.

I have also just done a bulkhead swap on my 110 but that was part of a larger rebuild after an engine fire so cannot give a time estimate to that. One thing I would say if you are fitting a new bulkhead is take the time to seam seal, paint and fill every internal surface with some form of cavity wax before you fit it. it is much easier to manipulate to do that while it is bare and off the vehicle.

Have you thought about galvanizing your new bulkhead before fitting?

Another vote for doing it yourself. I think you'll regret it if you don't get it galvanised while you have the chance!

Superaquarama said:

Hi Guys,
Having just completed the resto of an 86", next in the queue is replacement of the Defender bulkhead and got a warm-climate rust free one ready to paint.
Question is, whether to have a go at it myself or farm out the job? Anyone any idea of the hours / pitfalls for a reasonably competent amateur, or the hours for a Landie specialist who's done them before?
Thanks,
Anthony

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I’ve just changed my bulkhead on my 90…it was ok. Not the easiest thing to do but can be done with a help from someone here and there. Every nut n’ bolt is done by you so you know it’s done proper and you do get the satisfaction of sound it. I had an engine crane to do the mail lift out and in. I built the bulkhead back up with the dash parts and then the engine bay side of things. I just took my time and worked away at it. Lifted it back onto chassis and connected all the wires pipes etc and engine running… She sounds smooth. Just can’t get my battery light to go off now Hope you get it done ok. Take your time and enjoy it….and listen to some 80’s music while you’re at it. Gary Davies radio 2 2000-2200hrs every saturday

I did mine outside on a driveway. You will find other stuff that needs doing, that will hugely increase the cost if a garage does it for you. Removed and installed by just me, using care and an engine hoist. Yes, it will take a lot of time, depending on what other problems you find.....

Forrest Gump said:

I’ve just changed my bulkhead on my 90…it was ok. Not the easiest thing to do but can be done with a help from someone here and there. Every nut n’ bolt is done by you so you know it’s done proper and you do get the satisfaction of sound it. I had an engine crane to do the mail lift out and in. I built the bulkhead back up with the dash parts and then the engine bay side of things. I just took my time and worked away at it. Lifted it back onto chassis and connected all the wires pipes etc and engine running… She sounds smooth. Just can’t get my battery light to go off now Hope you get it done ok. Take your time and enjoy it….and listen to some 80’s music while you’re at it. Gary Davies radio 2 2000-2200hrs every saturday

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I had similar issue with battery light on mine. There is a thin Wire in the dash that runs from the centre (behind stereo) to behind the instrument cluster that got cut. When i re joined the Wire the battery light went out. (I think the Wire was white but i can't be 100%)

Thanks for that tip, I’m going to go and check that tomorrow then. This light coming on has been hard to fathom out and I have next to no experience with electrics. I’m trying to keep as many of the original parts as I can. I’m rebuilding it onto a new chassis and bulkhead. Thanks

Superaquarama said:

Yes, you're probably right ! We're on the Wales - Shropshire border, near Montgomery. Galvanised chassis.

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I'm in welshpool, I did mine a few years ago, not the nicest job, but do-able with time and patience.
If you want a bit of help let me know, tea and biscuits is all I charge

I'm in welshpool, I did mine a few years ago, not the nicest job, but do-able with time and patience.
If you want a bit of help let me know, tea and biscuits is all I charge