Bulkhead Swap - continuing.

Well it's been another good weekend (in between feeling really really ill).

Finished off the wiring and containment to the fans and it looks pretty neat and works!

Then lots of tidying around the dash, fitting new switches, installing stereo and fixing the fault with the loom!!! Well done to Ed who found the problem. Its all sorted and every thing works as it should.

Jobs still outstanding inlcude

• Refit wheel arches
• Refit airbox
• Get screen fitted
• Fit dash vent trims
• Fit speakers
• top up all fluids and bleed systems
• Fit door cards.
• Fit new speedo cable into transfer box

Bulkhead swap nearly finished

Well its been good progress over the weekend with only a few "minor" items to finish.

First off the OS wing was fitted, with PAS reservoir, expansion tank and radiator support arm.

Then I fitted the headlight, side light and modified the wing to take the new Td5 style indicator. Then on went the NS wing which had the heater flow unit attached, followed by radiator support arm and grill surround.

I then fabricated a frame unit for the two fans, as before they where mounted via a cable tied through the radiator and the wrong way round!

I then mounted the new fan frame with fans. and reinstalled the bonnet pins and support bar.

Next I fitted all lamps to the front, washer bottle with pipes and wiring. I also started the wiring to the fans. While I was doing this Ed arrived to lend a hand with the wiring loom, mainly changing connectors for nice new waterproof versions.

Quickly tonight I re installed the front doors, at the same time replacing all bolts for stainless versions. Looking like a Defender again!

Jobs left to do include:

Fit bumper

Fit Air box

Connect up front indicators

Get Nation wide to fit the glass (I was going to fit myself but they were cheaper!)

Sort the wiring loom so that the controls work! And then finish off the dash unit.

Yes, few problems with the loom, it seems that a few electrical items currently don't operate. Might need to spend a day or so poking around (Ed), either way bit of a nightmare. So if your a auto sparky or know your way around a Defender loom get in touch!!!!

Bits that don't work:

Headlights

Indicators (but hazards do)

Wiper motor

Washers

most dash lights

brake lights

reverse light

fog light

Bits that do:

Starter motor

hazards

side lights

dash light for side lights

Any ideas let me know! Might save me a few days of poking around.

Refitting Bulkhead Continued

Well as I hoped progress over the weekend was good. I started out by putting the heater unit onto the bulkhead.

I then fitted the top water hose.

The lower dash then went on to better support and help organise the wiring loom

The the new style dash fascia was installed. I have decided to use this 2003 style dash fascia as I think it looks smarter.

I'm also opting for a Raptor dash, so both the lower dash and dash fascia had to be cut to allow fitment.

Here is the dash with the carcass of the raptor dash fitted, I think it looks very smart and will look even better with the dash panels and switches fitted.

Next I cut an refitted the vent control lever covers, there is a slight compatibility issue here so I've had to glue them in.

At this point I have taken out the LPG system and fitted the screen frame.

After much thought I've decided that I'm not happy with the dash finish around the vent controls, so I will be making my own out of aluminum. Here is the first cutting I have made. This will be sanded and painted black.

For most the weekend Ed has been lending hand trying to deal with the wiring loom, A job which I hate the look of, so thanks to Ed!

Refitting of the Bulkhead.

Things have started to move forward over the last couple of weeks, heres the progress made to date:

The bulkhead has returned from painting, while it was off I added to it the steering column, accelerator and brake pedal. I also popped in the washer jets and waxed the inside to prevent rust.

As you will be able to tell from the coming photo's I have decided on a colour, thanks to the 2 people that voted from the right colour! Epsom Green it is! ( I did say I wouldn't listen to the vote.)

Once I found someone to give me a lift I fitted it to the Defender.

After the bulkhead was fitted I reconnected the steering link, sills, rubber grommets and clutch pedal.

I then fitted the wiper motor and assembly. I have decided to use the Td5 wider set that was already fitted to the new bulkhead.

The remaining parts of the clutch system have been fitted.

Got my new transmission tunnel cover, this type is for the R380 gearbox (which mines not), so it required some modification. First off it was cut to ensure it fitted, then screws where added to form a start for the fiberglass.

Then I extend the lip around the new opening with fiber glass. All this work seems a bit odd as I already have on the fits, but I do have a plan! Inside the cab I want to use the Exmoor Trim molded matting system, however they do not make a version for the V8 and have no plans to. So by using a trans tunnel cover for a R380 gearbox I can use the equivalent matting system! Although the matting system will need to be cut slightly to allow for the modifications I have made. I'll also need a custom gear stick gaiter! There is still a little bit of work left to do.  The end nearest the seats has a large gap where the new tunnel sits much higher than the old one. This will be filled with some sort of high density foam.

Next few tasks where fitting the internal dash skin, this needed to be cut to allow room for the Td5 wiper motor. The fuse board has been screwed into place and I've started to re thread the loom through the bulkhead.

I also glued into place the vent seals and fitted the flaps. 

Thats all for now, hopefully progress will be good over the weekend now I have now course work to hand in! (well for a few months at least.)