Hi all,

Now the MOT is all sorted and done, i've started to look towards the summer and my task is going to be to fit a new bulkhead, as the current one is a little worse for wear and i managed to pick a fully dressed td5 one up off ebay.

Got a tiny repair to do on footwell and then it's good to go.

But since there's a lot of the bodywork to come off for that, i am thinking of going further and getting the seatbox, rear bulkhead and rear tub off and cleaning the chassis up a bit. It's solid, but has a little surface rust so am thinking of sanding it down, high zinc painting and then some hamerite (or another paint if it'd be better....).

I'm going to replace any bolts I come across as from past experience so far, they'll be very rusty!

Is there anything else I should look at doing whilst I've got the bodywork off?

Also, will I need to replace anything else when I fit the td5 bulkhead? I've read so far that obviously wiring loom will need to be swapped, which shouldn't be too much of an issue.

There's some conflicting posts whether the tunnel will fit or not, I notice buster has done this already, i've had a good search and couldn't find anything (apart from the excellant howtos on removing all the bits i'll need to take off before the bulkhead can come off!).


PS also this is a 2002 (i think) td5 bulkhead going onto a 1992 200tdi 90
Cheers

There is threads. Rebuild. Bulkhead etc. while tub is off u could replace the brake pipes if needed and tidy up the suspension paint the axles Breather pipes service the tranny and gearbox oils Bushes replace ? Not much else. Waxoli inside the chassis Td5 will fit but slight mods need etc as I understand. Don't ask me I have never done this

Replace breather pipes. Not paint it. I mean paint the axles.

only mod needed to fit a td5 bulkhead is use the tunner part off your old bulkhead screws into place

td5 bulkhead tunnel


lt77 bulkhead tunnel


thats all i did when i did my rebuild and your better off fitting new hinge bolts and the special clip bolts for the bulkhead wile off there only 20p each and worth it for future replacing of the doors

Excellant cheers for that, looks like that bit will be a little easier then.....there's a little more repair to do on the bulkhead though, which is annoying! Nevermind...