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daslandroverman

Series Bulkheads

12 posts in this topic

Thought my current project might generate a bit of interest here...

Everything begins with a rusty bulkhead from a IIB Forward Control. It could have been repaired, but to my mind by the time I'd done so it would have been 90% new metal by the time it was done properly.

A bit more thinking left me with the notion that it wasn't going to be much more difficult to build a new one from scratch. So, tape measure out, lots of measuring done, drawings made, and I ended up with a stack of sheet metal in various interesting shapes.

Some work with a large press and other sheet metal forming devices started to make them look more like Land Rover bits.

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And with a bit more fettling they started to look even more like Land Rover bits.

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Then after drilling some holes and adding some weld it got closer still.

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Until something resembling a complete new unit had come into existence.

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Said unit has proved some of the drawings were spot on, others not so, and has also contributed some to getting the assembly sequence sorted.

A few mistakes and other updates required mean that this unit will be cut up shortly, and rebuilt again (more completely) using updated components.

However -and you are reading this right- complete Series II/IIA bulkheads will be available at a reasonable price quite soon.

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Congratulations for persevering with this project.

Am I reading this correctly, you started to design and build a replacement FC bulkhead, but having 'cracked' the processes involved, you are now moving on to take advantage of the bigger market by making complete Series II/IIA bulkheads?

Don't take me wrong, it's a good idea, and perhaps I've made a wrong assumption, that an FC bulkhead is different to a Series II/IIA bulkhead.

I am not going to split hairs about the detailed differences that I'm assured occurred during the lifetime of the bonneted Series II/IIA. Within context I am absolutely certain that there is a strong market for a middle of the road 'generic' Series II/IIA bulkhead.

I'll leave the arguments about detailed differences to the nit-pickers present on the Series 2 Club Forum :-)

Regards.

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And Lightweight vent panels?

They make big money!

G.

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Congratulations for persevering with this project.

Am I reading this correctly, you started to design and build a replacement FC bulkhead, but having 'cracked' the processes involved, you are now moving on to take advantage of the bigger market by making complete Series II/IIA bulkheads?

Don't take me wrong, it's a good idea, and perhaps I've made a wrong assumption, that an FC bulkhead is different to a Series II/IIA bulkhead.

I am not going to split hairs about the detailed differences that I'm assured occurred during the lifetime of the bonneted Series II/IIA. Within context I am absolutely certain that there is a strong market for a middle of the road 'generic' Series II/IIA bulkhead.

I'll leave the arguments about detailed differences to the nit-pickers present on the Series 2 Club Forum :-)

Regards.

Correct. I've sussed it.

The FC bulkhead is different in details to the standard II\IIA bulkhead, but the basic structure is the same from 1958-1972. It's not intended to be a concours accurate replica depending on chassis suffix or model year, but a relatively accurate unit that's un-noticable to 90% of people, and still agreeable to those who know the details they're looking at.

General reception from the Series 2 Club is also positive, especially from those who've seen the first build.

would you be looking at doing defender bulkhead aswell?

if at what cost?

It wasn't something I'd yet considered, but as a Series III unit is likely on the cards -SWMBO's SWB needs one- then a Defender type unit isn't a huge leap further forward.

As it's still possible to buy decent ones for £5-600 I'm going to concentrate on Series stuff for the immediate future.

And Lightweight vent panels?

They make big money!

G.

Have you been reading my notebook? Yes, they are also in development.

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Well done! I've seen many attempts at this over the years. I remember someone in Bolivia with a metal brake making his own. This has always been one of the most brilliant things about these cars, that so many parts can be made without a huge workshop.

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Nice work...sheet metalwork is something I'm not overly good at, prefer machining big heavy lumps!

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So, since I last posted there's been quite a bit going on in the workshop. 

First off, I can now do SWB truck cab filler plates, having gotten my hands on a genuine parts one to copy. 

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A lot of reworking, testing and altering has gone on, learning lessons from the original build.

Most parts have had some sort of alteration, but it's pretty much there now.

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Then lots of clamping, welding, measuring, adjusting, measuring and tickling with hammers.

Then it was fitted into the jig to get built up fully.

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And with the inner panel sat in to test the fit.

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The footwells look like they'll fit rather well also.

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As an added bonus I've sold a few full width top section repair panels. The blanked off vent holes will be a production option should you wish it.

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For more regular updates you can find my page on Facebooks if you search for Westlakes All Wheel Drive.

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Very impressive - I really envy your skills !!

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I don't do Facebook.... But I would like a series bulkhead, keep us (and me) in mind when you've got some prices! ;-)

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