Hi! I'm new here, but not new to Land-Rovers.
I am rebuilding my 1961 Series II 88 Station Wagon, which I've had since 1980, and have built up the vehicle on a new (probably Richards - can't be sure as the supplier hasn't confirmed who they actually got it from) galvanised chassis. We bought a new galvanised bulkhead from the same supplier, I do know the manufacturer of this but don't want to say whilst I'm in dispute with them. There have been many problems and I have not been able to get a satisfactory fit still. When on the vehicle, the tumble home line of the bulkhead is 10mm below that of the rear body, this is partly because the bolt holes in the chassis outriggers are 4mm lower than the originals. The hole for the steering column was at least 10mm too far to the left but the problem I can't solve is that the angle of the sloping part where the vent panels are is 3° too much. This makes the door tops - even a genuine new-old-stock one I've had for years - touch the bulkhead when the vertical shut lines are about right. Obviously the problem gets worse when the windscreen is fitted, and is exacerbated by the fact that the windscreen is 5mm too far back.
So, here's the questions.
I believe that the windscreen angle, measured from the old bulkhead should be 25° back from vertical, the new one is 28°. What should the angle be?
The distance from the tumblehome to the centre line of the bolt through the outrigger is 584mm on the old bulkhead but 578mm on the new one. 6mm shorter. What should this measure?
Is it usual to fit spacers between the chassis and the bulkhead to get the door shut lines wide enough for the doors to work? I've currently got 5mm spacers here but there were none on the original. I don't remember how it was 'as built' as I replaced the outriggers in 1981.
The outriggers I fitted in 1981 have crush tubes welded through them for the bolts but the new chassis has square plates 9mm thick welded and no tube. What arrangement was originally used.
If the chassis is basically right then the problems with the bulkhead are worse! I shall probably cut the reinforcement plated off the outriggers and weld them back higher up if they are wrong.
I've pretty much lost patience with the bulkhead fitment and will either have to buy one from another company (Owen or Pegasus), or give up and sell the vehicle for parts!
Any ideas?
LR Series 2 Bulkhead Errors-Model.pdf