stumpyj
Active Member
- Posts
- 113
- Location
- Perth, Scotland
Hi Everyone
I'm building up courage to repair the top of my bulkhead in my 2000 TD5. Its not too bad but it is rusting and has had some pretty ropy repairs to the passenger side where a patch panel was welding over the existing metal - it came from a quarry so it was probably just a working fix. I've got some repair panels from YRM which are brilliant, although they dont have holes for the bolts for the window frame/bulkhead pre drilled. The worst of the rust is right on the edge where the panel folds under the window frame - otherwise I would have just welded the new panel minus the lip.
Anyway my mate is a fantastic welder and has given me a day of his time a week on Saturday to weld in the repair.
My plan is to remove the 3 bolts holding the bulkhead to window frame and I would like to be able to raise up the window frame enough to remove the old seal and gain access to that area. I really dont want to remove the complete window frame as this doesnt leak and will probably cause more issues?
I believe there are some locating pins in the bulkhead so I wont be able to just cut out the old metal as I need to keep them in place??
The top of the repair panel has a lip, and the easiest solution would be just to weld in this to the back of the bulkhead, however the locating pins?
Do I remove the top door hinge and keep the door in place so that I can then ensure that the repair panel is in the correct place to ensure a good door fit, or remove completely. I'm concerned that things wont line up when its done. I said this to my mate and he told me to wind my neck in!
Any suggestions appreciated. Im dreading it but know that at some point it needs to be done. I used dum dum putty along the window/bulkhead and to be fair have never had a leak. I presume I can re-suse the fly screen behind the existing vents as they are abit pricey to replace.
I've done most of the renovation myself and tbh every time someone has said "thats easy" its turned out to be an absolute nightmare- A Frame Ball Joint, Core plug replacement..
I know I should have done this when I was renovating her last year, but I just concentrated on the mechanicals and chassis - that was more than enough hahaha.
Or - do I just live with it!
Thanks
Stumpy
I'm building up courage to repair the top of my bulkhead in my 2000 TD5. Its not too bad but it is rusting and has had some pretty ropy repairs to the passenger side where a patch panel was welding over the existing metal - it came from a quarry so it was probably just a working fix. I've got some repair panels from YRM which are brilliant, although they dont have holes for the bolts for the window frame/bulkhead pre drilled. The worst of the rust is right on the edge where the panel folds under the window frame - otherwise I would have just welded the new panel minus the lip.
Anyway my mate is a fantastic welder and has given me a day of his time a week on Saturday to weld in the repair.
My plan is to remove the 3 bolts holding the bulkhead to window frame and I would like to be able to raise up the window frame enough to remove the old seal and gain access to that area. I really dont want to remove the complete window frame as this doesnt leak and will probably cause more issues?
I believe there are some locating pins in the bulkhead so I wont be able to just cut out the old metal as I need to keep them in place??
The top of the repair panel has a lip, and the easiest solution would be just to weld in this to the back of the bulkhead, however the locating pins?
Do I remove the top door hinge and keep the door in place so that I can then ensure that the repair panel is in the correct place to ensure a good door fit, or remove completely. I'm concerned that things wont line up when its done. I said this to my mate and he told me to wind my neck in!
Any suggestions appreciated. Im dreading it but know that at some point it needs to be done. I used dum dum putty along the window/bulkhead and to be fair have never had a leak. I presume I can re-suse the fly screen behind the existing vents as they are abit pricey to replace.
I've done most of the renovation myself and tbh every time someone has said "thats easy" its turned out to be an absolute nightmare- A Frame Ball Joint, Core plug replacement..
I know I should have done this when I was renovating her last year, but I just concentrated on the mechanicals and chassis - that was more than enough hahaha.
Or - do I just live with it!
Thanks
Stumpy
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