Bulkhead Welding

Bob Fenton · Jun 12, 2018

I'm thinking of buying a Defender 90 which is in need of some restoration. Most of the work I can do myself but it's going to need some welding on the two upper corners of the bulkhead and that's beyond my level of ability.

Before I commit to buying the vehicle I'd like an idea of what would be the likely cost of getting the work done and does anyone know of a competent welder in the Surrey/Hants area?

Many thanks.

Kitai · Jun 12, 2018

Photos would be helpful, maybe it's not even necessary to weld! Does it have holes?

Have you checked the rest of the bulkhead, i.e. footwells from the inside and from engine bay and floor panels?

Generally you'd have to remove the windscreen frame and dash, grind down to bare metal und cut out the parts you can't rescue. Then cut the repair panel to fit and THEN weld in and repaint. If you can do some of the work the welding itself will only be a minor part.

dag019 · Jun 12, 2018

If you are going to do all the prep work as mentioned above it could be fairly cheap as you could get a mobile welder to come to you.

Or you could do what I did when I bought my series. Cost up the price of repairs, decide it is very expensive and instead spend the money on buying a welder and a welding course at the local agricultural college. Although it was no cheaper o do it this way for the initial repairs, it has paid for itself 10 times over in the years since. It is amazing how much you find that needs welding once you can weld! You also suddenly become an invaluable friend to an one local who also owns a land rover.

Bob Fenton · Jun 12, 2018

Unfortunately I can't supply pictures. One side is much worse than the other but it's definitely a welding job!

There is also a bit of work to do on one of the footwells but that is clearly straightforward.

If I use a mobile welder I can definitely do the strip down to reduce the cost. The question really is about the magnitude of cost, is it £10's or £100's.

Bob Fenton · Jun 12, 2018

dag019 said:
If you are going to do all the prep work as mentioned above it could be fairly cheap as you could get a mobile welder to come to you.

Or you could do what I did when I bought my series. Cost up the price of repairs, decide it is very expensive and instead spend the money on buying a welder and a welding course at the local agricultural college. Although it was no cheaper o do it this way for the initial repairs, it has paid for itself 10 times over in the years since. It is amazing how much you find that needs welding once you can weld! You also suddenly become an invaluable friend to an one local who also owns a land rover.

Ha, ha. That would be a great plan if I had more time. I already get a bit of grief for spending too much time tinkering with the car!

dag019 · Jun 12, 2018

have a look one here to price up the repair sections you may need (link). They are also available from other places so may be worth shopping around to get the best price but YRM are very god suppliers (no connection)
After that to get a price it depends on how much work there is to do which is difficult without photos. I would have thought it is unlikely to be in the £10's but should not run into huge figures unless it is worse than it sounds. May be worth phone around a couple of local people, agricultural places will be used to land rovers so will know what you are talking about.
A colleague of mine had the sills of his terrano repaired in the work car park by a mobile welder and cost him £120 for two large patches.

Bob Fenton · Jun 12, 2018

dag019 said:
have a look one here to price up the repair sections you may need (link). They are also available from other places so may be worth shopping around to get the best price but YRM are very god suppliers (no connection)
After that to get a price it depends on how much work there is to do which is difficult without photos. I would have thought it is unlikely to be in the £10's but should not run into huge figures unless it is worse than it sounds. May be worth phone around a couple of local people, agricultural places will be used to land rovers so will know what you are talking about.
A colleague of mine had the sills of his terrano repaired in the work car park by a mobile welder and cost him £120 for two large patches.

Thanks, that's very helpful. I'm probably looking at £50 max for the bulkhead repair panels so hardly worth shopping around.

When can you come and fit them??

dag019 · Jun 12, 2018

Bob Fenton said:
Thanks, that's very helpful. I'm probably looking at £50 max for the bulkhead repair panels so hardly worth shopping around.

When can you come and fit them??

By the time I have calculated m expenses it would put you off buying it in the first place

Kitai · Jun 12, 2018

Did a four-day welding course myself and decided to better keep practising a bit more before I actually apply my new craft to my beautiful Defender!

dag019 · Jun 12, 2018

Kitai said:
Did a four-day welding course myself and decided to better keep practising a bit more before I actually apply my new craft to my beautiful Defender!

It is by working on it that you do practice. That being said being able to weld has meant that I make a lot of things I would previously have bought. This also helps with the practice, like the folding bbq griddle for use over a open fire I now use when camping.

Kitai · Jun 12, 2018

dag019 said:
It is by working on it that you do practice. That being said being able to weld has meant that I make a lot of things I would previously have bought. This also helps with the practice, like the folding bbq griddle for use over a open fire I now use when camping.

True that. It was actually a specific course for creating and welding body parts for cars. We built a little car door. I should know something about welding by now :-D

bluedog333 · Jun 12, 2018

The welding part itself doesn’t take too long, getting the windscreen out, wings off, roof raised etc etc is time consuming. Plus you’ll need to do it all in reverse once the new panels have been painted.
I wouldn’t be surprised if a garage wanted £700/£800 to do it.

nobber · Jun 16, 2018

I would take the whole thing off, get it sand blasted, have it welded up then galvanise it, that's what I would do.

Bulkhead Welding

Bob Fenton

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Kitai

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dag019

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Bob Fenton

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Bob Fenton

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dag019

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Bob Fenton

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dag019

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Kitai

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dag019

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Kitai

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bluedog333

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nobber

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