Bonnet hinge fitting

defender 90, G reg. new galvy bulkhead.

I have new hinges (see photo) and trying to fit with the bushes, but all i’m doing is damaging paintwork!

1) are these hinges ok for my 90 or is the bulkhead bracket different on later defenders?

2) the bushes are really brittle. Broken two already! But they have a thin and thic edge. What side should go towards the bulkhead?

3) seems too complicated to fit the bonnet with the hinges on, so should I fit the hinges to the bulkhead and then bolt onto the bonnet?

thin to the front and its best with two people to drop bonnet in to the bushes vertically

jamesmartin said:

thin to the front and its best with two people to drop bonnet in to the bushes vertically

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Should the bushes be difficult to fit into the bulkhead hooks? I am hammering them into place, and cannot rotate them round the right way (hence broke a couple due to my heavy handed screw driver!)

should slide in easily as they have to rotate freely

Looks like I need to bend the hinges back a bit then....

that or clean the galv out with a file or emery

Bend out a fraction if its smooth.

Rorie said:

Should the bushes be difficult to fit into the bulkhead hooks? I am hammering them into place, and cannot rotate them round the right way (hence broke a couple due to my heavy handed screw driver!)

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I had exactly the same issue on my galv bulkhead. Luckily for me I spotted it before it was painted. I ended up filing the slot in the hinge a little wider, to make fitting the hinges easier. I then hammered the hinges open slightly. I used a cold chisel between the top of the hinge and the bulkhead. It wasn’t pretty, nor gentle, but it seems to have worked.

Tomorrow evenings job is now sorted! Haha
Thanks

The hinge brackets aren't easy to bend. Big bar needed.
Go gently otherwise your bonnet will be out of line.
Slide bushes in from the side, hole facing up, thin bit towards the bulk head.
Hold the bonnet vertically and drop into place.

Glyn D said:

The hinge brackets aren't easy to bend. Big bar needed.
Go gently otherwise your bonnet will be out of line.
Slide bushes in from the side, hole facing up, thin bit towards the bulk head.
Hold the bonnet vertically and drop into place.

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I thought the bushes are supposed to have the thin bit at the front of the vehicle?

mick 1986 said:

I thought the bushes are supposed to have the thin bit at the front of the vehicle?

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Nope thin bit upwards when the bonnet is closed, thin bit facing the bulkhead when bonnet is vertical.

Thin side to the bulkhead,that's how they are on mine.

I would file a bit off the bushes rather than beat the bulkhead hinge.

zeaphod said:

I would file a bit off the bushes rather than beat the bulkhead hinge.

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One of mine had hollow sections, probably from cheap ****e plastic and poor manufacture. The bulkhead hinges get a coat of galv, and must move slightly as the metal cools. It’s not a huge amount it needs bending, maybe 1-2mm.