Replacing door pillars and bulk head corners

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harris hawker

New Member
Posts
109
Location
Cheshire
Ok i need some advice before the grinder comes out:D
After having a good look over my series 2a i have found some good bodge jobs have been done on both of the doors, passenger side has been bolted all the way though into the footwell and the top of the pillar is goosed, the drivers side the bottom hinge has been welded in place due to a crap plate welded to the pillar and the top is not much better, so i have ordered two bulk head repair corners and door pillars.
Now am i right in thinking that when i do the bulk head corners i will cut ot the bad and trim the new to fit in flush and then weld them up and gind it smooth???
but i have no idea where to start with the pillars? so could do with some much need advice please:)
 
i still need to do the btm door pillars on mine , guess you have the full length ones, the btm is located by the chassis so thats ok, just need to take plenty measurements so it butts up well with whats left, dont think it wouold make much difference whioch was first as long as enough sound original bits to line up to
90truckcab has done it on his rebuild see above thread
 
i still need to do the btm door pillars on mine , guess you have the full length ones, the btm is located by the chassis so thats ok, just need to take plenty measurements so it butts up well with whats left, dont think it wouold make much difference whioch was first as long as enough sound original bits to line up to
90truckcab has done it on his rebuild see above thread


Yes the bottoms are ok, one just needs plating on the top thats all. I have read 90truckcabs thread but he shows before then after and not the middle bit:D
From what i have seen the door pillar has a small flange at the top the allows the bulk head corner to sit flush and then the captive nut holes line up, i will just bite th bullet and go for it, i will prob the roof and do lots of measurements has the doors dont really line up to well at the minute :rolleyes:
 
I did one on my series 3 last year . bottom corner post passenger side had rusted away .The trick is to find the spot welds by removing the paint and drilling them out .the door bottom hinge bolts will also need to be drilled out as they often corrode. these should be replaced with new captive nuts that slot into the new corner post. the holes drilled for removal are then spot welded and ground off

Part of the floor pan inside the cab will need to be removed by grinding to gain access to the spot welds alternately work from underneath with a chisell

Geoff
 
As G Claxton says, drilling out the spot welds is the key in bulkhead work. It can be tricky as the spot is harder than the surrounding steel. Some of the guys on the line went a bit crazy with the spot welder. I did a full restoration of a IIA bulkhead (off the vehicle) using a special hardened centre bit from Paddocks (the kind with a spike in the middle of the cutting faces). Around 25 welds each side. Worth the effort though.
 
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