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Likeomg

Member Since: 29 Jun 2012
Location: Lake District / Newcastle
Posts: 2641

2010 Defender 90 Puma 2.4 HT Stornoway Grey

Bulkhead removal bar

Going to remove my bulkhead this week.

does anybody have any photographs of this process? a friend of mine who is one of the top restores of escorts and the like in the country has agreed to do it, he will make a top job just if i had some photos to help, i found some in mcma1's gallery but wondering if anybody has others?

the plan is to use the tool normally reserved for cutting sunroofs in cars to take the majority of it out...

19th Apr 2015 3:02pm

gilarion

Member Since: 05 Dec 2013
Location: Wales
Posts: 5110

2007 Defender 90 Other CSW Trident Green

Instructions and photos here click on the fitting instructions once the page has loaded

http://www.mudstuff.co.uk/bulkhead-removal-bar.html For those who like Welsh Mountains and narrow boats have a look at my videos and photos at..

http://www.youtube.com/user/conwy1

19th Apr 2015 3:05pm

Likeomg

Member Since: 29 Jun 2012
Location: Lake District / Newcastle
Posts: 2641

Hi sorry, I'm going with the full removal and the tubular bar in its place...

19th Apr 2015 3:33pm

gilarion

Member Since: 05 Dec 2013
Location: Wales
Posts: 5110

In that case there are few pics here half way down the page that might help

http://www.eastcoastrover.com/148.html For those who like Welsh Mountains and narrow boats have a look at my videos and photos at..

http://www.youtube.com/user/conwy1

19th Apr 2015 3:46pm

sharkey964

Member Since: 05 Oct 2014
Location: On a muddy track
Posts: 574

2007 Defender 90 Puma 2.4 XS CSW Santorini Black

I did mine myself last year.
first thing I would say,is strip all the seats & carpets out first,the ally filings are a

to get rid of after.
The rear sides need taking out,but you don't need to take the roof off.I supported mine with a couple of lengths of 2" x 2".
Sorry no pics of during,just after.
They are in my gallery.
Marc

19th Apr 2015 5:08pm

TDCi Guy

Member Since: 17 Aug 2014
Location: Yorkshire
Posts: 286

1996 Defender 110 300 Tdi HCPU Auto Keswick Green

Probably a bit late but I referred to this guide when I installed mine.
http://www.paddockspares.com/media/downloadable/DA1810_vr1.pdf

Instead of leaving the bits of ex-bulkhead sticking out with the rivets in I added some angle ally onto the inside corners of the wheel boxes to hold the end face to the rest of the wheelbox. After looking at a mate's TD5, this is how Land Rover did it, although fixed with spot welds.

I also drilled out the captive nuts on the top of the side supports so that I could fit the bolt from the bottom. This meant I could slide a nut in between the tub and the van sides rather than have to unbolt the entire roof and sides to drop 6 bolts in! Tom
@tditomprice
100” Defender Hybrid
2010 Alaska White 90 HT

28th Apr 2015 12:40pm

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