galvanised bulkhead

I am going to be fitting a galvanised bulkhead to my '88 series III. I know in theory how to go about this and have read up on other threads and write ups of people who have done this previously. However I do not know what i will need other than the new bulkhead. I would like to have everything I am likely to need ready before I start the job.
So what else is likely to need replacing, or break in the process of swapping them over?

Be prepared for lots of nuts and bolts that won't come off and will need cutting, a new seal for the bottom of the windscreen and seals for the vent flaps too and pedalbox to pedal housing seals/gaskets. Be prepared for the wiring behind the dash to be a mess from previous bodges, it also goes hard and brittle and may crack when you remove it or spades might be loose. The S3 dash might have hidden rust in it too and has a few fiddly parts.

Nuts, bolts, seals, rubbers, angle grinder blades, tea bags and patience

I was expecting to need to replace all of the nuts and bolts. I will make sure I have all the seals and gaskets. Where in the dash is likely to be rusty? i have a spare (all be it beyond repair) bulkhead that is complete with dash so hopefully between the two i will have enough good pieces of dash board.

Is it possible/worth while to get a replacement bulkhead wiring loom?

who are you getting you galvanised bulkhead from? think i might have to go down that route soon

Landrover77 said:

who are you getting you galvanised bulkhead from? think i might have to go down that route soon

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That was going to be another one of my questions. I have found a place in Birmingham (classic bulkheads) which is relatively local to me. It also coincidental seems to be the cheapest place to get them. However I do not know what they are like and was wondering if anyone else had used them, and knew what sort of quality the final product is. They are not new bulkheads but repaired and galvanised second hand ones.

yep i came across them also... did you find ash tree international?

Landrover77 said:

yep i came across them also... did you find ash tree international?

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I did but they are much more expensive, and much further away from me for inspecting and collecting the bulkhead.

A Birmingham supplier, that is of interest. There are a few Brum based makers of door tops/bottoms also one in Rugeley that I found when having motorcycle parts powder coated. The coaters where running a batch of doors through for an outfit on the same industrial estate. Is it a secret to let us know the Brum supplier ? I do not need a bulkhead but someone local will.

Taps an dies to remove galv from tapped holes and a dremel or similiar to get the vent hinges cleared of excess galv.

dag019 said:

That was going to be another one of my questions. I have found a place in Birmingham (classic bulkheads) which is relatively local to me. It also coincidental seems to be the cheapest place to get them. However I do not know what they are like and was wondering if anyone else had used them, and knew what sort of quality the final product is. They are not new bulkheads but repaired and galvanised second hand ones.

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Company called Pegasus not sure where they are based, and from memory 2 grand for a new bulkhead and 6 month wait, mental money.

divie said:

A Birmingham supplier, that is of interest. There are a few Brum based makers of door tops/bottoms also one in Rugeley that I found when having motorcycle parts powder coated. The coaters where running a batch of doors through for an outfit on the same industrial estate. Is it a secret to let us know the Brum supplier ? I do not need a bulkhead but someone local will.

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classicbulkheads.com give their address as being based in Olton. £675 for a restored and galvanised bulkhead on an exchange ;policy. but they currently do not have any in stock so would need to restore your current bulkhead with the three month lead time. I am going to dive them a call at the beginning of the week and find out some more information. I was just wondering if anyone had heard of/used them before and had any experience.

Galvying costs about £150 per 100kg if you have a lot done so one bulkhead costs Approx £50 to get dipped. that means they're charging £500+ to do the welding. FFS for that money I'd expect a new bulkhead.

Pikey said:

Galvying costs about £150 per 100kg if you have a lot done so one bulkhead costs Approx £50 to get dipped. that means they're charging £500+ to do the welding. FFS for that money I'd expect a new bulkhead.

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Agree with this, get a good 2nd hand one and get it patched then dipped at:

1. Arkinstall Galvanizing Ltd
   
2. Metal Finishers
3. Address: Dudley Road West, Oldbury B69 2PF
   Phone:0121 522 0500
   

They have a really good reputation, near brum, and have been recommended on here before I believe, and definitely on the S2 Forum. I'm taking all my cappings, windscreen etc for dipping and they have a £100 minimum order, and can even get the stuff blasted if necessary.

Pikey said:

Galvying costs about £150 per 100kg if you have a lot done so one bulkhead costs Approx £50 to get dipped. that means they're charging £500+ to do the welding. FFS for that money I'd expect a new bulkhead.

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This is the same process that ashtree use where an original bulkhead is re-manufactured and then galvanised, and they are charging £900+vat.

If you know somewhere I can get a new series 3 bulkhead for a under £500 I will buy buy that and galv it myself. The last new one I saw they wanted nearly 2k for a new old stock one.

darius said:

Agree with this, get a good 2nd hand one and get it patched then dipped at:

1. Arkinstall Galvanizing Ltd
   
2. Metal Finishers
3. Address: Dudley Road West, Oldbury B69 2PF
   Phone:0121 522 0500
   

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I have used them before when I have had bumpers and tree sliders done for my 110. My problem is finding a decent bulkhead to get galvanised.

Going back to the original question, I don't think I'd bother trying to get EVERYTHING ordered at once.

As you strip, you're going to find stuff that needs replacing that's purely incidental - but you can get at more easily. So, as you go, just keep a list and get orders in relatively little-and-often.

Let's face it, you're going to be doing this over a period, so it's unlikely you'll get stuck for a day or two for bits, if you're thinking even just a step or two ahead. If you do, there'll probably be other areas you can get on with whilst you wait.

TooMany2cvs said:

Let's face it, you're going to be doing this over a period, so it's unlikely you'll get stuck for a day or two for bits, if you're thinking even just a step or two ahead. If you do, there'll probably be other areas you can get on with whilst you wait.

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I am hoping not to be doing this over an extended period of time as it is kept in an open barn at a friends farm so not the most secure location to have a vehicle in pieces. I have a second bulkhead that I was going to get refurbished and glavanised and then hoped to just remove the old one, swap everything onto the new one and refit. Hopefully, if everything comes off easily and I have all of the parts that will need replacing, all completed over a long weekend.

Re the wiring, 80% of a Series 3 loom is in the bulkhead, the rest are the engine and light feeds basically. Autosparks do new ones if required. The dash goes rusty in the lower part where the heater ducting is, although is usually not too bad.

A good cavity wax will do as good a job if done properly and maintained and will be cheaper?