Can you help? Bulkhead /Brakes

I have a 1993 Defender 90 that has developed quite excessive corrosion at the top corners of the bulkhead underneath the window screen. I have seen repair sections available for these areas on Ebay and wonder has anyone has used them and how easy they are to fit. Am I putting off the ineviatable and should I consider replacing the whole bulkhead? Once again is this a huge job or could I do this myself.
Finally I went to take my front brake caliper off yesterday to find that the previous owner has rounded off the bolts so that it can't undo them. Any suggestions as to how I should tackle this problem as I need to replace the discs and hub bearings

Many thanks

Skippy

Those caliper bolts aren't Hex headed as you might expect - they're a sort of 'multi-hex' - dunno what the correct name for it is - as would fit exactly into something like this:



IIRC they're a 14mm bolt head and it might look like they're rounded off if they're a little rusty.

If they're actually rounded off you could re-face them to fit a spanner or socket 1 size lower onto them - failing that drill through the head and drive an old drill bit through it to use as a lever. Molegrips might wrok, but I doubt it. They're loctited in usually, so giving it a good belt of heat should break the loctite down.

Well worth replacing them when you do get them out as they're kind of critical (LR Genuine parts from a local stealer cost circa £4 when I did mine I think)

Cheers,

Bi-Hexagons if they have 12 points as I suspect.

Use a top-quaity bi-hex socket.

If that fails, it is usuaslly possible to get a nifty welder chum to Weld a good nut onto the heads of the stuck bolts.

The heat helps to loosen them.

Buy new bolts and a can of copper-grease.

CharlesY

theres sockets available from Irwin (screwfix, machine mart etc) that are designed specifically for removing rusted on / painted on / seized/ rounded off bolts - I bought a set and was doubtful they'd do much but they are amazing.

I even went out and bought a further set of bigger sizes they are that good. With one of them, a 1/2-3/8 adaptor and a breaker bar, they'll shift ANYTHING. Oh and penetrating oil does a sterling job too.

I thought I could get away with those corner things until I had a look under the windscreen framey bit and discovered the whole top was knackered. It's a fairly big job to replace but just nuts and bolts. If you get a TD5 bulkhead you'll have to do a bit of cutting and welding to get it to fit. Nobber has recently done his and posted some pics.

Wot they said about yer brakes. Cept I'd use locktight on the bolt threads at the end and then copperslip on the rest making sure you dont get any on the locktight. Try a bit of heat on the bolts if there that stuck.

Thanks for your replies. Looks like I'll have to get the blow lamp out this weekend. Once again Cheers

Skippy