Anyone know book time or a fair estimate for bulkhead replacement? - Defender Source
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Old August 7th, 2009, 03:17 AM
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Anyone know book time or a fair estimate for bulkhead replacement?

Trying to get an idea of what would be a fair number of hours for an experienced mechanic to remove and replace a bulkhead on a NAS D90 or D110. I have no desire to do it myself (too many irons in the fire and it would take me months probably to actually get it done), but thought I would have my mechanic do it, but neither one of us knows what would be a good estimate for time. Assume there is not any severe rust, but that the screw head bolts will need to be drilled out. I thought ballpark would be in the 16-20 hour range but I have never done just a bulkhead. My plan is to fit the new galvy bulkhead I have and then repair the old one and have it dipped and do this until all my trucks have galvy bulkheads
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Old August 7th, 2009, 04:05 AM
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Paul Beckwith
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It took us a couple of days working flat out to make the change on a tdi - removing the bulkhead is pretty easy - its removing the wings, dash, doors, loom, screen etc etc thats a PITA.
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Old August 7th, 2009, 10:19 AM
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We = two people?
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  #4  
Old August 7th, 2009, 04:21 PM
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Paul Beckwith
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Yea - sorry - two of us............both amateurs!

I know you are going to have a local tech do yours, but for anyone else contemplating having a go, you need lots of containers for things like dash parts and screws etc etc and take loads of digital photos to refer back to, as its really easy to reassemble in the wrong order or foget where something goes.................

Paul
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Old August 8th, 2009, 08:29 AM
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Chris Hinkle
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Having done this by myself, the main issues were: all the rusty bolts that you will find in all the out of the way places, getting new gaskets and making sure you take lots of photos to make sure everything goes back together correctly. The bulkhead is the first thing that goes on the frame when you start a build, so if you are going to change it you almost need to go down to a rolling chassis. With the wings, doors, windscreen, rollcage, tunnel, heater, A/C and floors having to come off - you might as well take of the rear tub and seatbox - check everything over and use stainless hardware to put back together.
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Old August 8th, 2009, 03:51 PM
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Carey
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PM some details. Would consider a weekend trip for some decent beverages and a Pat's or Geno's
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Old August 8th, 2009, 03:54 PM
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Carey, will do.

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