Start of the Bulkhead Swap

Take a look at my Defender from here on in this will be the last time she looks like this. I now commence the restoration.

Time to remove the Bulkhead.

I started with the doors and moved on to internal trim and unbolting the wind screen, which didn't fall out as I expected and seemed to be welded into position. I decided to remove that later on.

Next removal of the dash unit and disconnecting the switches and gauges, labeling as I go (Shall see if that helps at all when it comes to reconnection!) Towards the end of the day Ed arrives to lend a hand; starting to remove the front grill and wings. I move onto the floor pan, and drilling out every single floor screw there is! Meanwhile Ed has made a lot of noise and fuss about something and removed the front grill and lights. I then take out all pedal units while Ed starts unbolting the NS wing and all that is attached to it. (I say unbolting however something's Ed decided not to unbolt, like the heater matrix. Instead opting for the pull, tug, twist and swear, which did eventually remove the unit, but in doing so the breather pipe connection which enters the alloy air tube from the carb was snapped off, which is nice. Another little extra job to keep me busy. Guess that's what you get at BMW main dealers - Brutality)

 End of day one.

I start the day with removing the OS wing, taking off the wheel arches to access the bolts to the bulkhead, removing all attached and mud shield fixings. Then move on to the NS wing same thing again.

Then removing the wiring from the bulkhead, trying to find out what wiring does what and where it goes, labeling it up, and pushing it through. I'm just hoping it works as well in reverse! The loom on this vehicle is crazy and its not helped by the addition of the LPG system were the colour coding of wires seems to be random. Ed turns up half way through the disconnection of the loom and removes the steering column.

Once all this is done we attempted to remove the windscreen. But it's pretty stuck. So we do what should have been obvious from the start and unbolt the B pillar from the roof, bit more forcing and its out!

The end is near just a few more bolts and the bulkhead will be removed, and I will have a Defender which is completely useless and static. Joy.

The end result; feels pretty strange sat in the drivers seat with just an engine up front.

Last job of the day is to compare the new and old bulkhead, cut out the holes required, patch the unneeded holes and plaster it with seam sealant ready for painting.

Inspection of the old bulkhead proves that a swap was defiantly needed, rot had truly set in and the repair job was very poor. The repair job on the OS consisted of painting the bulkhead grey, which wasn't particularly affective.

Next task: rust proof all I can see of the chasis, clean and paint any brackets before re-install.

Big thanks to Ed for helping out, I really couldn't have broken all that stuff with out him. (only joking, thanks mate)

Fitting Bonnet Catches (Aero Catches)

Well I have now amassed a number of parts including the suspension package. There are a few more parts which are still required but these will have to wait to next pay day.

I have a couple of small jobs which I can tackle now one of which is my newly acquired bonnet catches.

I have opted for catches opposed to the cable operated cabin handle as it will save me having to refit the old handle when it comes to swapping the bulkhead and avoiding the clash between old and new, instead now I can remove completely. Plus it looks pretty neat.

Out of all the bonnet pins available I chose the Aero Catches as they give you the ability to lock the bonnet and they are flushed fitted which I prefer.

 

The first problem I found was find a suitable position to mount them, due to the defenders bonnet shape, catch size, hole position and wing position there was no place I could mount them. So I made a bracket to support the pins which was mounted of the radiator supports. 

With the steel section cut to the correct size it was time to remove the existing bonnet catch and spring.

I then fixed into place the steel support bar with 2 rivets.

 

Once this had been complete it was time to start measuring to determine where the pins would come through the bonnet, this tool a while! eventually I thought I had worked it out, and drilled my first hole in the bonnet. I then closed the bonnet and marked the hole position on to the new steel bar. 2 hole where then drilled into the steel to take the bonnet pints. The pins were installed, bonnet shut to see if the holes where in the correct place. They where out by a few mm. So I used the template and centered it onto the pins and marked the hole which was required in the bonnet for catch fitment.

Then it was time to try out my new nibbler, great tool, however it did struggle to get the tight turn at the bottom of the catch. I then filed the holes to remove the tight spots and finished where the nibbler couldn't reach.

I then fitted the catches into the holes, drilled the holes for the bolts and then bolted them both into place. Quick test to ensure the pins fitted and after a quick location shuffle the hard bit was done. The only issue with the pins is caused by the angle of the defenders bonnet I.a. it slopes down to the nose of the car and as a result so does the catches. This means that when the pins enter the catches the rub slightly as the pins are straight. Had I put more thought into I could have angled the pins. However they work fine as they are so that's how they'll remain.

Next I removed the support bar and painted it to stop it rusting up.

Once painted it was then re-fixed but with 4 rivets this time, the pins were leveled up and the rubber bumpers added.

Job done, and I think it looks good. But it will look better when the defender isn't beige!