Back to the Bulkhead Section
Please be aware that ECR is now a Defender repair and modification shop only.
We no longer work on Range Rovers, Discos or Series Rovers.
These pages are from work we did in the past and left up for your enjoyment.
Series IIA Bulkhead Repair
This Series IIA bulkhead, or should we say, what is left of it, has come to us from a customer that is doing his own restoration. We will be doing the bulkhead metal work, and he'll be doing the rest. The good news is that this bulkhead has a very good upper section. The only rust is low in the footwells and tunnel. The bad news is that, as is common with 30-40 year old bulkheads, this one has had a lot of extra holes drilled in it over the years, and we'll need to fill all those up with steel as well. We'll also be making some changes to the bulkhead to get it ready for the more modern dual power brakes, Mansfield heater and more. On this unit we had to remove a lot of pieces to get down to the bulkhead itself. If you are looking to get a bulkhead done at the best price possible, check out our bulkhead F.A.Q. That would have saved this customer some money. Next we'll cut all the rust away and media blast the bulkhead to find the hidden rust and damage.
The image above shows the bulkhead top section in our jig. We have cut away the rusted footwells and door posts and have sandblasted the rest of the bulkhead so that we can be sure to find any thin areas or rust pin holes. In the jig you can see that we have started to install the new door posts and feet that will make the bulkhead as good as new, and because it is jig built it will fit, and all the doors will line up properly once the Rover gets put back together.
After the major rust has been cut away, and a quick blasting has been done, the real hidden rust starts to show up. Here you can see that the inner tunnel area has some serious through rust, so we will cut all the corrosion and rust away and custom fabricate repair panels made from thicker steel to replace the areas.
This image shows the bulkhead with the jig arms removed. You can now see that the bulkhead is starting to look like a bulkhead again. The new feet and door post are in place, as are the footwells and top sections. You can also see that the footwells we use have the correct stampings in them for a correct factory look. These pieces are also lightly galvanized for ultra long life.
In this image you can see the rusted problem area on the tunnel cover from the image up the page has been completely cured. New steel has been shaped and welded into place and then ground flush. Doing it this way, rather than patching things on top of rust means a better, longer lasting repair, and it looks better too. You can also see that we have closed off some old rusty heater holes (the dark spot near the top of the image). The customer will be switching to a Mansfield heater, so these rusty openings are no longer required.
Next we'll move on to making the changes so that the customer can just bolt in the more modern updates he wants to run in his Rover, and then we'll remove the clamps and fully weld all the seams. This bulkhead will be painted elsewhere, but we will be running it through the dunk tanks so that it will have a good chance at lasting as long as possible.
Here you can see the SIIA bulkhead with all the steel work and modifications completed. We have made the openings for the Mansfield heater, so it will bolt in without any cutting of the bulkhead. We've also made the correct opening for the Series III style power brake pedal box, as well as filled some more non-factory holes that were in the front of the bulkhead. We have also fabricated the correct seal lip on the door posts so that the Genuine Land Rover door seals will fit correctly. Next we'll run the completed bulkhead through our "dunk tanks" so that in the long run rust will not be a factor.
This image shows the results of the ECR dunk tanks. You can see that the entire door post, and upper section have been fully submerged in tough, rust resistant primer. This floods primer in, around and behind all these areas of steel in the bulkhead and assures a long lasting repair. It is a messy job for sure, but one that needs to be done to make sure that an ECR jig built bulkhead is the best product we can produce.
Here you can see the completed SIIA bulkhead. All the rust has been removed and replaced with new galvanized panels and nearly every aspect of the bulkhead has been brought back to factory correct standards. It is like going back in time and getting a bulkhead from the 1960's, except that ours are better! They are made from better materials and will last much longer! The customer will be doing the final blasting, paint prep. and painting of the bulkhead as he completes his restoration, so this is the finished product, ready for delivery. This bulkhead is destine for a 109 Station Wagon, so a correct, jig built, bulkhead is essential so that the customer will be able to get the body lined up on his 5 door correctly.
If you have a rusted bulkhead that needs work, contact ECR. We can help make your SII-SIIA bulkhead better than new... just like this one.