Nintey 200tdi engine conversion

[Sigi_H]

I completely agree with Snagger, since I am alone quite often. A winch offers some kind of safety.

I used MT tyres for many years, they worked good as well, but I was many years on loud tyres and I really needed them only twice.

I now use silent AT tyres and have a winch, which offers the same safety in my eyes, when I am alone.

One restriction, however, is that there must be a way of attaching the cable, regardless of whether it is at the front or rear. I now have a ground anchor to attach it in every case.

 

[muzaz]

So, a little update -  the new galvanised bulkhead just arrived.

First impression...a bit of a mixed feeling, tbh I have never seen what an aftermarket bulkhead looks like but comparing this to the original, the orginal just looks sharper. Maybe it's got to do with the galv process which makes evertything looks more rounded?

There is some warping of the panels, mainly the footwells. The material looks a bit thicker than the original, again maybe because if the galv.

Overall it looks fine to me, all holes mosty clean off extra zinc  etc. There are some differences to my original bulkhead in mine was a pre tdi and this is a 300tdi, so there are some extra brackets etc. but should be fine.

So far the only defect I noted is missing metal surround at the two oval  holes below the vents.

Some photos will follow.

 

[muzaz]

Packaging, cardbiard box, quite thick but still git punctured at the bottom corner. Still made it tho!

Some warping is visible especially on the top of the footwells.

 

[muzaz]

Missing metal sorround, can take off my old bulkhead.

Footwells are single skin ribbed type.

Overall I think it's fine, much similar to the original one in the details.

[Retroanaconda]

That looks okay - hopefully it all lines up.

It will be worthwhile getting plenty of seam sealer into the open joints, and then once painted loads of wax into the cavities. 

[Stinkfloyd]

3 hours ago, muzaz said:

Missing metal sorround, can take off my old bulkhead.

Footwells are single skin ribbed type.

Overall I think it's fine, much similar to the original one in the details.

I was looking at these very bulkheads and will likely buy one. It will be good to see how you get on overall with fitment. 

 

Would it be possible to see a closer view of some of the welds please?

Edited April 12 by Stinkfloyd

[muzaz]

5 hours ago, Retroanaconda said:

That looks okay - hopefully it all lines up.

It will be worthwhile getting plenty of seam sealer into the open joints, and then once painted loads of wax into the cavities. 

Yes that's the plan will go round all the seams and edges, but first I think better treat the galv to etch it or age it slightly. Will have to see what's available locally.

Hope all lines up!! I can't really tell if it's waped or not, it looks pretty straight but some panels are sure have some warping.

2 hours ago, Stinkfloyd said:

Would it be possible to see a closer view of some of the welds please?

Here you go, any particular area in mind? Most of the welds are small short welds and spotwelds. Some are ground but most are not. 

 

[Sigi_H]

What a wonderful documentation! But unfortunately I missed the brand of the bulkhead. Which brand is it?

 

[muzaz]

I got it from SP4X4 but don't know what brand it is, no marking on it or the box. I assume they build them themselves. The documents say made in the UK.

[Sigi_H]

Thanks a lot
 

[Stinkfloyd]

7 hours ago, muzaz said:

Yes that's the plan will go round all the seams and edges, but first I think better treat the galv to etch it or age it slightly. Will have to see what's available locally.

Hope all lines up!! I can't really tell if it's waped or not, it looks pretty straight but some panels are sure have some warping.

Here you go, any particular area in mind? Most of the welds are small short welds and spotwelds. Some are ground but most are not. 

 

Thats brilliant, quality seems decent enough. It's always nice to see one that's actually been purchased by a normal customer. Quality seems good enough to live with looking at the photos and it's a good bit cheaper than some of the other offerings out there. Let us know how it fits up please of you don't mind 😁

 

Cheers

[Sigi_H]

As I didn´t paint my galv chassis, I think about leaving a new bulkhead unpainted as well. It looks good.

 

 

[Snagger]

Odd that they didn’t finish the wiring loom apertures, as you said.  The ovals are welded in on SIII bulkheads, but I have no idea how they are fitted on Defenders.  I’m sure you can bond them in if you can cut them out of the old bulkhead.

[Sigi_H]

I saw it too and my first idea was 3D Print.

Should be easy to print inside plates and outside boxes, which are fitting in exactly. To seal them is easy too. They can have any feedthrough you like.

For those who are not into that so much, they can take aluminium plates in- and outside. Aluminium is ok, because aluminium and zinc harmonise very well.

With a good seal between, they don´t have contakt anyway.

Edited April 13 by Sigi_H

[muzaz]

2 hours ago, Snagger said:

Odd that they didn’t finish the wiring loom apertures, as you said.  The ovals are welded in on SIII bulkheads, but I have no idea how they are fitted on Defenders.  I’m sure you can bond them in if you can cut them out of the old bulkhead.

I contacted them, they said they get them direct from LR and will ship me a pair next week. Fair enough. Yea they are normally welded in but I'll just seal them in. Actually I'll throw some cavity wax inside before I do.

6 hours ago, Sigi_H said:

As I didn´t paint my galv chassis, I think about leaving a new bulkhead unpainted as well. It looks good.

Well, not entirely sold on that. I would leave the chassis, bumpers and cappings, but the bulkhead I don't think I would. To be honest it would still blend in with the color I have in mind, which is light grey (BAC 707) but I don't know. For me it's part of the bodywork so I'd want to paint it!