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 III Bulkhead Repair
This Series III bulkhead has come to us from a customer that is doing his own rebuild in PA. The bulkhead is in pretty bad shape, as most Series III bulkheads are. For some reason the Series III bulkheads rust far worse then their SIIA counterparts. The good news is that this bulkhead is not past the point of no return, it is close, but we will be able to save it, and make it like new again. Above you can see that we have set the bulkhead in our bulkhead jig to check for any accident damage. Luckily in this case it appears to be rust is the only battle to fight.
Our first step is to go over the bulkhead and make the customer aware of what the bulkhead looks like and what it will take to repair it. As you can see above the bulkhead has all the typical rust in the footwells and door posts. These aspects are easy for us to repair.
The hard part about this bulkhead is the rust in other areas, where patch panels are not available. The red arrow above points to one of the many areas like this on this SIII bulkhead. Even before we media blast the bulkhead we can see that we are going to have problems here. The rust is already through the LH wiring passage and that means custom panels and time to repair, and that hole will get bigger when we blast the rust off.
Next step is to cut away the rusted areas that are too far gone to repair and then media blast the rest to see what we are really up against. You can see in the image above that the bulkhead gets cut back to the bare minimum in this process. The good news is that all new metal will go back in place of that old rusty British steel.
Media blasting always turns up new areas of damage and rust. In the image above you can see that the areas shown by the arrows have through rust that will need to be cut out and replaced, and as we mentioned, no patch panels are made for these areas, we will fabricate them here at ECR.
Sometimes surface rust turns out to be through rust as well. A light area of what looked like surface rust turned out to be through rust in an odd place on this bulkhead. That is why the blasting is done, to find all the rust and get rid of it to then replace it with new steel.
Here you can see another area that needs attention. The lip that would attach the footwell pieces to is rotted away except for a small section. All this jagged rusted mess will be cut away and new fabricated panels put in its place.
Once we media blast the rusted areas we cut away all the rusted steel so that we have a clean white metal base to work from. Above you can see that the areas with the rust pin holes has been completely removed back to good steel.
Then new repair panels are cut and sized and then tig welded into place. We do not just patch over the rust like most repair shops, we remove the rust completely, then inset new steel. If you leave any rust it will come back.
This image shows that problem area of the bulkhead with the new steel in place and rough ground. All the correct contours are there and once the area is prep'd and painted no one will ever know a repair took place.
Here you can see the new floors have been installed and the lower area of the tunnel has been repaired. The same rules apply, we don't just put patches on top of your old rusty parts, we cut out the rust, then put in all new steel for a long lasting repair. If you are doing a restoration on your Series Rover, you don't want to be taking the bulkhead out again a few years down the road. You can also see above that the floor panels we install have the correct pressings to duplicate the factory look and are zinc coated for long life, much longer than the factory panels.
Above you can see the new door post has been installed. The customer plans to use the stock door seals, but the door seal lip rusted off years ago and the new door posts do not come with the lip on them. To make the bulkhead factory correct, we have fabricated the new door seal lip and installed it down the length of both door posts so that the customer can install his chosen seals with ease.
Here you can see the bulkhead ready to head over to our paint department. The fabrication is complete and the bulkhead is now ready to be fully media blasted back to white metal and then dunked and primed and made ready for the customer. At the customers request we have set up the bulkhead for a Mansfield heater as well, that way once the primer is applied the customer will not have to cut or drill any holes in the bulkhead, it will remain sealed with primer as all the holes and modifications are pre-done.
In this image you can see the bulkhead has been dunked in our dunk tanks to get rust resistant paint inside the trouble areas on a bulkhead and then the exterior has been media blasted back to white metal. What you see above is bare metal, ready for primer, as you can clearly see there is no rust of any kind on this bulkhead.
The bulkhead is then moved to our spray booth where numerous coats of PPG epoxy primer are applied so that the bulkhead is sealed and ready for the customers choice of paint.
Here you can see the finished product, ready to go back into the shipping crate and head back to PA. The bulkhead has been fully restored to better than new condition, dunked and primed with epoxy primers to assure a long life for the customers Series III. The customer can now complete his rebuild knowing that his bulkhead is not an issue. It will fit correctly, look perfect and likely outlast the rest of the panels on the Rover.