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dhopable

Member Since: 31 Dec 2012
Location: Peterborough
Posts: 47

2007 Defender 90 Puma 2.4 HT Tonga Green

Extra legroom? Bulkhead Removal? Seat Rails?

Hi guys,

Im new here so bear with me!

Ive got a Puma 90 HT, and am 6'4. Not a great combination as you can imagine!

Ive been thinking about doing the Mud bulkhead removal for a while but am worried about cutting the bulkhead. Has anyone done one and is it an easy job to do?

Ive been quoted £400+vat from my local overland specialist which is obviously alot more than buying the bar and growing a pair and doing it myself.

Im not completely incompetent and could probably manage it, but i've only had the Defender for a few months and still in that new romance period! If you know what i mean..

Also will the rails be necessary as well? Ive been told there is no point fitting the rails without removing the bulkhead because you get no extra room?

I've scoured the site and all i could find is a thread posted back in August when someone did one. But he said it gave too much room?!

Any help or advice would be much appreciated!

Cheers
Doug

4th Jan 2013 8:00pm

Tiger

Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

Did the mud removal bar on my 110

Pretty easy, just time consuming and messy!

4th Jan 2013 8:08pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6102

The mud rail thing doesn't really help when the bulkhead is still in place.... you need to be able to tip the back of the seat back a bit too; well, that's what I found.

I also found that the mudrail (well, my own version made of 3/4" box) raised the seat a bit too far up too, and I ended up looking at the sunvisor instead of out of the screen (6'5" here)

Once I cut the bulkhead out, i could tip the seat back that little extra more, and it made things much better.

4th Jan 2013 8:15pm

Killer90
Site Sponsor

Member Since: 09 Oct 2011
Location: Hertfordshire
Posts: 6478

2016 Defender 110 Puma 2.2 XS DCPU Fuji White

£400 + vat is alot of money for a job like that, it is a relativity easy job just go for it, instructions are very clear and make a hell of a lot of difference in the cab for leg room

CSK Automotive
www.cskautomotive.co.uk
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4th Jan 2013 8:28pm

dhopable

Member Since: 31 Dec 2012
Location: Peterborough
Posts: 47

Ok great, thanks for the help (and motivation!)

Ill get the bar ordered and get it fitted. Ive got a couple of angle grinders, will that cut the bulkhead neatly or do i need to get a reciprocating saw or something similar?

4th Jan 2013 8:40pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20468

dhopable wrote:
Ive got a couple of angle grinders, will that cut the bulkhead neatly or do i need to get a reciprocating saw or something similar?

Providing you have a small diameter disc you should be okay and not a wide one. Either that or a jigsaw with a metal cutting blade which would be more precise. Either way make sure you cover everything up for protection from swarf or sparks! No Guts, No Glory.
ðŸ‡¬ðŸ‡§ðŸ´ó §ó ¢ó ¥ó ®ó §ó ¿ðŸ´ó §ó ¢ó ·ó ¬ó ³ó ¿ðŸ´ó §ó ¢ó ³ó £ó ´ó ¿ðŸ‡®ðŸ‡ªðŸ‡ºðŸ‡¸â›½ï¸ðŸ›¢ï¸âš™ï¸ðŸ§°ðŸ’ª

4th Jan 2013 8:43pm

Killer90
Site Sponsor

Member Since: 09 Oct 2011
Location: Hertfordshire
Posts: 6478

dhopable wrote:
Ok great, thanks for the help (and motivation!)

Ill get the bar ordered and get it fitted. Ive got a couple of angle grinders, will that cut the bulkhead neatly or do i need to get a reciprocating saw or something similar?

As Steve said, use a Jigsaw to cut it out or a mini powered hacksaw to get a nice precise cut and less mess and sparks

I hate grinders

get plenty of pics aswell and remember check twice cut once

CSK Automotive
www.cskautomotive.co.uk
Like us on Facebook - www.facebook.com/csklr
Follow us on Instagram - @cskautomotive

4th Jan 2013 8:50pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20468

Killer90 wrote:
I hate grinders

Likewise, They can be nasty if they get pinched or suddenly grab into the metal. Much like a chainsaw grabbing into wood and "jumping" back. Could easily do some serious injury to hands / fingers. No Guts, No Glory.
ðŸ‡¬ðŸ‡§ðŸ´ó §ó ¢ó ¥ó ®ó §ó ¿ðŸ´ó §ó ¢ó ·ó ¬ó ³ó ¿ðŸ´ó §ó ¢ó ³ó £ó ´ó ¿ðŸ‡®ðŸ‡ªðŸ‡ºðŸ‡¸â›½ï¸ðŸ›¢ï¸âš™ï¸ðŸ§°ðŸ’ª

4th Jan 2013 8:53pm

dnorrishill

Member Since: 15 Jul 2011
Location: Hampshire
Posts: 616

2014 Defender 90 Puma 2.2 XS CSW Aintree Green

I am planning on installing one of the station wagon type bars in the near future, £125 last I checked, but I think it will be more work to install?

http://www.britpart.com/Accessory.aspx?AccessoryRef=5317

I also found a blog post that details the whole removal process:
http://projectd90.blogspot.co.uk/2011/05/b...1.html?m=0
http://projectd90.blogspot.co.uk/2011/05/b...2.html?m=0
http://projectd90.blogspot.co.uk/2011/05/b...3.html?m=0

Last edited by dnorrishill on 4th Jan 2013 9:21pm. Edited 1 time in total

4th Jan 2013 8:57pm

dhopable

Member Since: 31 Dec 2012
Location: Peterborough
Posts: 47

That does look good but i want to keep the lower part of the bulkhead in place. Otherwise i think all the stuff in the back will slide forward!

Plus there is normally a dog in there and Ive got to try and fix the dog guard back in place after ive done it, further back i think. Its one that bolts to the tub tho so not sure how im going to do it.. Need to sort something out or the little cocker will have his muddy little paws all over the dash in no time!

4th Jan 2013 9:13pm

993porky

Member Since: 01 May 2011
Location: sunderland
Posts: 171

Hi mate if you need dog guard have a look at this defender for sale on eBay item eBay Item No. 190778695098 the bloke has used a cargo net as a dog guard to be fair it's a simple idea and personally think its a canny idea if you are wanting to remove bulkhead,save you trying to fit your rigid dog guard back

4th Jan 2013 9:46pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20468

There is also half height dog guards sold by LR as well as full height for SW's so if you were converting a bulkhead to remove it you could go from current half height to full height and take it out completely. Just something to bear in mind. Personally myself I love my bulkhead left as is and with half height dog guard.

Then again I am 5'11" so don't really have any issues with room. No Guts, No Glory.
ðŸ‡¬ðŸ‡§ðŸ´ó §ó ¢ó ¥ó ®ó §ó ¿ðŸ´ó §ó ¢ó ·ó ¬ó ³ó ¿ðŸ´ó §ó ¢ó ³ó £ó ´ó ¿ðŸ‡®ðŸ‡ªðŸ‡ºðŸ‡¸â›½ï¸ðŸ›¢ï¸âš™ï¸ðŸ§°ðŸ’ª

4th Jan 2013 10:03pm

TooTall

Member Since: 10 Jul 2012
Location: Fens
Posts: 504

6'4'' Meh - Dwarf

I'm 6'6'' but the TD5 has no A/c so

but pls let me know how you get on... "Ease your worries, Clear-up your woes,
Go into your garage & put stuff into rows."

4th Jan 2013 10:19pm

Tiger

Member Since: 06 Jul 2012
Location: Wales
Posts: 2265

For the Mud rail.

I used angle grinder and normal metal blade. 4"?
Jigsaw
Drill
Pop Riveter

It's not hard, the instructions kinda make sense.

It's very neat when done, really pleased with mine, top bit of kit.

Take the front seats out, dust sheet everything!

Metal bits gets everywhere!

4th Jan 2013 10:21pm

me@td5.org

Member Since: 16 Jan 2011
Location: Warwick
Posts: 856

I have mudrails and a P&P bulkhead removal bar. I still want more space. I' 6'6" but all legs.

4th Jan 2013 11:47pm

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