muzaz

Engines, gearboxes and mechanical parts in general are fairly easy to change or replace. Body/chassis repairs are not. Have a good look at the bulkhead.

Good, one problem less! Thanks. Tomorrow will cut the vent panel out to discover the horrors underneath.

Yes I think thats correct, but do they clip directly to the door post, or there should be some part of the bulkhead frame which supports it. For example, the windscreen frame hinge where it is attached to the top bulkhead, under the skin there is an internal structure. Is there anything similar for the doors? Would like to find some photos or drawings of the internal structure but cant find any. Just found photos of rust and holes 🤭

Any idea of what the internal structure under the bulkhead skins should look like? Took the pillar off and found nothing...surely the door hinge must attach to some sort of internal reinforcement. Mine was two nuts welded onto the pillar.

I meant, strange it rusted out so badly in its first 7 years of existence! UK weather must be really hard for Landrovers! The damage I'm finding now, 30 years later, was mostly under already repaired sections or hidden with body filler. At first looks it looked fine, no obvious heavy rust. Only when I started taking things off and poking here and there the problems came out. I'm fine with some surface rust, not a big issue, and anyway as you said after repairs and cavity wax, should hopefully be good for a long while!

I'm reluctant to galvanize it, heard some stories of warpage etc and I have enough trouble at hand! The curious thing is this, the truck is 1988 yom, in 1995 it was exported and registered locally. All repairs to the bulkhead appear to have been done before being exported, so that means in the first 7 years the bulkhead suffered extensive rusting. Both lower footwells, bulkhead top corners and driver side vent were repaired.

Looks good! Did you lift it?

Thanks for the replies, will go for 16x7" ET-25. Will see how much they cost to ship them. As for tyres I can find Toyo MT local to me, not cheap tho at 240€ a pop.

I'm after a set of mach 5 style wheel for my defender 90 but getting a bit confused on selecting the right size. https://4x4tyres.co.uk/brand-name/challenger/#pa_wheel-size=4884 The tyres I want to fit are 255/85r16 Toyo Open Country MT. The wheels I'm seeing have different widths and different offset: 16x10" ET-32, 16x8" ET-20 or ET-32 or ET-35, 16x7" ET-20 or ET-25 Any suggestions which way to go please?

A new galvanized bulkhead is out of my budget, they are very expensive locally. If I manage to fix the rot I'm seeing and give it a good dose of wax and sealer inside, it should hopefully outlast me!

Always good to keep friends! You can thin it with acetone to the consistency you need and pour it...you won't find it in the instructions 😜 Yes, was there, moved on to Srt.

If you have friends working on aircraft you might borrow some PR1440 polysulfide sealant.

Given the extent of the damage to the top sill of the bulkhead, I see no other way round it, the frame had to come off. Can't weld the repair piece in with the frame in place. Took the frame off completely, mosty stuck because of the bead of sealant.

Managed to take the frame off...had to slacken the roof bolts and pulled it up with a chainblock as it was too tight. Popped right off from the bulkhead and remained attached to the roof! Yes there are 4 dowel pins on the bulkhead so it was useless pushing it! This is whats left of the bulkhead under the windscreen frame...not much steel left 😞 Got the repair sections ordered from SP4x4. Will probably have to fabricate the underlying structure tho.

Thanks for the encouragement! Giving it a go, nothing to loose! Does the roof need to come off to take the windscreen frame out? I have the hinges off and 8 screws from the top of the frame, but it looks like it's not getting off any time soon. Is it bolted to the bulkhead other than the two hinges?

I've owned a warco lathe and mill for 7 years and they serve me well. Granted they are not at the same level or even near a Bridgeport or a Colchester and you wouldn't want them if you were a productive machine shop. But for a hobby machinist I believe they are useful. I have faced the cylinder head and machined the transfercase bush on mine with no issues.

I'm starting to have second thoughts whether I should have repaired the bulkhead or got a new one! 🤔 The more I try to fix, the more damage I find! Now I found the driver side internal windscreen bracket attachment rotten, and some rot under the windscreen frame rubber seal. So that's the windscreen frame out, I was really hoping I wouldn't have to do that! Anything I should be aware of before attempting to take the windscreen frame off? Looks like it's only held by the two hinges at the far sides of the bulkhead. The top looks like a seal or sealer?

Thanks! Trying my best, the Lidl flux core welder did a very good job! I'm a bit wary of this next repair job. I'm afraid of what I'll find when I start cutting in the rust!

So it's time for updates... Have good and bad news 😕 Passenger side repairs mostly done, footwell replaced, bulkhead internal hinge area repaired, front chassis dumb iron repaired... Bad news, the driver side is in a bad shape. Existing repairs rotting out, door pillar rotten, door hinge same as the passenger side - rotten and the vent surround gone! Repaired section door hinge area. Rot removed new parts fabricated and welded in. Footwell rivetted and sealed. Should hopefully not rust again during my ownership! Front chassis rail repaired as best I could! Back to square one, not sure how I'm tackling this. It's obvious someone has been at it before as I can see welded patches and a good amount of filler. The door pillar and bottom support bracket is also rotten. Arrgh.. hate bodywork!

I would say they are similar to what I got, but a much different price!

Yep, not much help! Says JLB on the seal, google says it's a bearing company...all in chinese tho!

Bearing finally arrived, the dimensions are spot on 22x36mm so the column will need some fettling to get the bearing to fit. No big deal as I got a lathe, but I think a good rub with a sandpaper will work just as well. The bearing came in a plastic bag with some chinese letters, no brand name. On the seal I can read 61904RZ JLB which could be a part no. However a google search gave me a bearing 20x37x9mm which it is surely not!

If you get an HD intermediate shaft from Synchro Gearboxes, get a couple of extra o-rings as well. The shaft is an interference fit in the bush and has a tendency to bite the o-ring.

The size seems right, but as you said, expensive. The pair I ordered were 15€ each, still expensive for what they are but better than a complete column, just hope they fit. Once I get them, I'll update you if they fit properly and the part no

Dieselpumpuk have all things OM606. Something like this? https://dieselpumpuk.com/products/land-rover-2-2-or-2-4-puma-mt82-to-om605-6-adapter-kit