How do I check for hidden bulkhead corrosion

johnnyoxford · Feb 20, 2010

I have a couple of small holes, one to the side of where the bonnet hinge fixes to the bulkhead, and the other similar in size (about 1cm), where the hinge for the vent flaps is spot welded on.

I know I need to deal with these, but how would I be able to check for further hidden bulkhead corrosion that might not be obvious at first glance?

Do I need to take the whole dash off inside to inspect it?

Also what can be done as preventitive measures?

thanks (defender 90 200 tdi 1993).

Sean · Feb 20, 2010

johnnyoxford said:
I have a couple of small holes, one to the side of where the bonnet hinge fixes to the bulkhead, and the other similar in size (about 1cm), where the hinge for the vent flaps is spot welded on.

I know I need to deal with these, but how would I be able to check for further hidden bulkhead corrosion that might not be obvious at first glance?

Do I need to take the whole dash off inside to inspect it?

Also what can be done as preventitive measures?

thanks (defender 90 200 tdi 1993).

flap wheel in an angle grinder and take paint off till you hit metal, or more likely to be the case - lots of rust

johnnyoxford · Feb 20, 2010

do you mean around the existing corrosion? To find its true extent?

What about behind the dash where you cant see? Or under the bonnet?

Sean · Feb 20, 2010

johnnyoxford said:
do you mean around the existing corrosion? To find its true extent?

What about behind the dash where you cant see? Or under the bonnet?

everywhere - if you start taking the dash out you can be sure you'll find plenty and before you know it you'll be having the entire BH out, unless you wear a stetson

johnnyoxford · Feb 20, 2010

here are some pictures, would appreciate opinions from anyone who has dealt with similar?

thanks

steve-o · Feb 20, 2010

To be honest that doesn't look too bad.

If it were me i'd get some Hammerite Kurust and brush LOADS on and in the affected areas. Turns it black and solid.

johnnyoxford · Feb 20, 2010

could I do that, and then repair it with filler?

steve-o · Feb 20, 2010

I would just leave it and the reapply Kurust every few months.

Sean · Feb 20, 2010

johnnyoxford said:
here are some pictures, would appreciate opinions from anyone who has dealt with similar?

thanks

isn't so bad really - but there'll be a thumb sized hole under the window frame sealing strip - and plenty more hidden by the shiney looking paintwork

treating the bits you can see now will be like painting the forth bridge

johnnyoxford · Feb 20, 2010

is it easy to remove the mesh inside the vent flaps? If so I could get inside and get some kurust, waxoyl, hammerite in there, and maybe pack some filler in from the inside and then smooth it off from the outside after. At least that would stop some of the water running in that hole?

Sean · Feb 20, 2010

johnnyoxford said:
is it easy to remove the mesh inside the vent flaps? If so I could get inside and get some kurust, waxoyl, hammerite in there, and maybe pack some filler in from the inside and then smooth it off from the outside after. At least that would stop some of the water running in that hole?

you've never seen a naked bulkhead i guess ?

johnnyoxford · Feb 20, 2010

no i havent to be honest

pos · Feb 20, 2010

There are no two ways about rust and preventing it. Once it's started, it's there. That is unless you cut away ALL of the metal that has started to rust and then paint it well, but it'll still rot away from the inside over the years. I found a small pin prick hole on the corner of my bulkhead the other day. I then thought I'd check to see the state of the rest of the bulkhead, so began about stabbing at it (with reasonable force) with a flat headed screwdriver. I managed to open out a total of five holes, each one within the region of 25MM X 15MM. The bulkhead is a relatively thin steel frame which is then covered in another relatively thin steel skin. I can guarantee you (as Sean said) that if you took the dash out and the window frame out, you'd fine holes and rust all over the place. If you're not comfortable about it, set aside a week and strip it down and find everything you can. If it looks alright, patch the rusted areas or splice new metal in and then paint it back up. You might even go as far as swapping the bulkhead, which isn't supposed to be so much of a hard task, just irritating and time consuming. That locktite stuff that turns rust "back into metal" is utter bollocks. I coated what were good condition door bottoms in the stuff and then painted them. They've now rotten right through and are non existent two and a half years later because they rotted from the inside out. I've filled the holes in the bulkhead and painted over them for now, although I'd rather there was metal there.

If you take the carpet / rubber mats up in your cab and remove the rubber covers from your transmission tunnel, that should give you a good idea as to what shape the bulkhead is in towards the bottom, and you'll be surprised to find how thin the whole structure is. They do rust, thats why they make replacements. It's just not the nicest feeling thinking that you're driving around in a rot bucket.

-Pos

MrJC · Feb 20, 2010

You could at a push fit a couple of bulkhead repair panels and that would give you the chance to expose more of the inside of the bulkhead to treat, waxoyle? I know they wont cover all the holes.... of course.... you need to ensure you have good metal to weld onto. They are £10 each at Paddocks. LR62R Bulkhead repair panel - RH

arc · Feb 20, 2010

To be the bearer of bad news.....

Looks very similar to how mine looked before I sripped it down. Before poking, all I could see was bobbly paint just above where the wing joined the bulkhead.

During stripdown I did alot more poking ang ended up with a couple of holes ~10mm dia on each side - above wings and by flap hinges.

First big wake up was when I lowered the windscreen for the first time!

In reality it looked more like this.....

Lots of pics of my bukhead rebuild here.

Good luck - hope its not so bad!

pos · Feb 20, 2010

arc said:
To be the bearer of bad news.....

Looks very similar to how mine looked before I sripped it down. Before poking, all I could see was bobbly paint just above where the wing joined the bulkhead.

During stripdown I did alot more poking ang ended up with a couple of holes ~10mm dia on each side - above wings and by flap hinges.

First big wake up was when I lowered the windscreen for the first time!

In reality it looked more like this.....

Lots of pics of my bukhead rebuild here.

Good luck - hope its not so bad!

There's some sheer skill in the repairs there

bustersbus · Feb 20, 2010

Ooooooo, another chance tae show what it looks like when the front o' the bulkhead rots off

....

Mines was too far gone so ah had to replace it. What ah did was to bung up every hole on the new bulkhead and pour some zinc rich primer in there and then some paint...

fanatic · Feb 20, 2010

vimto

GRATCH · Feb 20, 2010

more similar here
90 project - Land Rover Photos

bustersbus · Feb 21, 2010

fanatic said:
vimto

Aye, it belonged tae me neighbour... honest

How do I check for hidden bulkhead corrosion

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