Easiest and quickest bulkhead change.

As per the title. What's the quickest and easiest way to change a bulkhead, anyone done it?

Pretty sure there is only one way, could be wrong.
Its not too bad, but the wiring harness is a pain. This caused me weeks of pain after it was put back together.
Wings off, screen off, doors off, floors out, tunnel out. Take lots of photos in particular of wiring connections. Pull wiring into the engine bay.
Unscrew all the crap that bolted to the bulkhead both sides - dash, wiper motors, steering, brake, clutch, heater - or you could leave all this on, remove whole and swap over to your new bulkhead and re-fit. Would be heavy though so would need a engine crane etc.
Roof can stay on. Seat box can remain. Engine and gear box was fine in place for mine.

Hmmm I dont have weeks.

Its a pretty integral part of the vehicle. Not to say someone with experience couldn't have it done in a day - but that's a very wild guess. I spent many weekends on it.
I guess that's why a lot of them are patched up and shipped out - just like mine was.

Yeah I've discovered that my bulkhead is basically molded filler. Not happy.

there is no easy way

Lots fiddling about scratching your head how to line things up, it will take time. I hope i'm wrong and your fits like a glove

windy81 said:

there is no easy way

Lots fiddling about scratching your head how to line things up, it will take time. I hope i'm wrong and your fits like a glove

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Looks like I'll be getting it done in a garage.

Pappasmurf said:

Yeah I've discovered that my bulkhead is basically molded filler. Not happy.

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That's bad luck, and unfortunately very common. If you opt for it, there's a fair bit on the net of people who have done it.
I'd say take a week off work and smash it out with late nights, but every time I've attempted that I've needed a part that I couldn't get in time or something else has happened - but you never know. I have a list of all the parts I used for my bulkhead swap if that's any use to you?

benpalmer said:

That's bad luck, and unfortunately very common. If you opt for it, there's a fair bit on the net of people who have done it.
I'd say take a week off work and smash it out with late nights, but every time I've attempted that I've needed a part that I couldn't get in time or something else has happened - but you never know. I have a list of all the parts I used for my bulkhead swap if that's any use to you?

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Always

As above, nothing difficult, just time. If (and it can be a big if on an old land rover) you don't have any seized bolts etc, I think you could have the old one off in a day - especially if you use a rattle gun to remove lots of the many bolts. Depending where the rot is, it may be possible to repair in situ - many people do exactly that. I have replaced footwells and pillars without removing the thing.

No reason why it cant be done in a day, it would be a long day, but if you have the tools, parts, a good workspace and know what you are doing then its a **** easy job to do. 3 hrs to remove old, 2 hrs to transfer everything across and another 3 hrs assembly.

nobber said:

No reason why it cant be done in a day, it would be a long day, but if you have the tools, parts, a good workspace and know what you are doing then its a **** easy job to do. 3 hrs to remove old, 2 hrs to transfer everything across and another 3 hrs assembly.

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That would be nice.

nobber said:

No reason why it cant be done in a day, it would be a long day, but if you have the tools, parts, a good workspace and know what you are doing then its a **** easy job to do. 3 hrs to remove old, 2 hrs to transfer everything across and another 3 hrs assembly.

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It terrifies me. Clearly when I’m ready to attempt mine, I will be calling on you

First off I have never done it, that out the way.

it would be an awful long day. the way I see it, it’s not the taking it off it’s all the stuff that breaks or need replacing to put it back together.
Well equipped I would allow at least 3 days. IMO

j

It's all fine and well, but I need somewhere to do it first. I don't have a garage or driveway, so I'd need to either find somewhere willing to lend me a garage/workshop space to do it myself, or pay someone else to do it.

Its not a difficult thing to do, you need to plan, have all the inserts, know what fabricating you need to do for wipers etc depending on the type of BH you are going to use, have clean, new nuts and bolts to hand, dont fanny about with rusty fittings, grind them off, have new floor screws, door screws and their captive nut fittings, mark the looms properly, this is how we work in a garage workshop to cut down on job times, we don't mess around,

Landyfox said:

It terrifies me. Clearly when I’m ready to attempt mine, I will be calling on you

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Dont let it, be confident, plan for it, and have fun.

for someone that's not done it, or no experience doing similar things it won't be easy and i very much doubt it'll be done in a day, but it'll be fun because you get to see how everything in that part of the car works and is fixed together