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  #81  
Old July 10th, 2014, 10:12 AM
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Quote:
Originally Posted by Wilboro View Post
Hopefully it doesn't require too much welding...but I know once it comes off there will be surprises.
You should not have many surprises when it comes to bulkheads. All the problem areas are visible and repairable in situ with the exception of the windshield support and heater box port. removing the lower dash or heater box will give you clarity there. We've got all the bulkhead repair panes from YRM in stock to make it a bit quicker/easier.

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Originally Posted by Wilboro View Post
I'm currently trying to create a master list of all the seals, grommets, bolts, nuts etc that will need to be replaced so I have it all ready for re-assembly.
Feel free to email me as I've got parts lists for the entire truck built.
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  #82  
Old July 10th, 2014, 02:47 PM
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Quote:
Originally Posted by Mybluett View Post
You should not have many surprises when it comes to bulkheads. All the problem areas are visible and repairable in situ with the exception of the windshield support and heater box port. removing the lower dash or heater box will give you clarity there. We've got all the bulkhead repair panes from YRM in stock to make it a bit quicker/easier.



Feel free to email me as I've got parts lists for the entire truck built.
I'm going to need the extended footwells minimum and would love to get that list. I'll shoot you an email shortly. Thanks!

Will
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  #83  
Old July 20th, 2014, 04:30 PM
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Deep into repairs on two bulkheads this week…

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  #84  
Old July 20th, 2014, 04:59 PM
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Brian who's spot weld cutter are you using ?
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  #85  
Old July 20th, 2014, 07:09 PM
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MyBluett - doing it that way can you get by with spot welding it all or do you needs to TIG/MIG some of the edges? Those YRM panels look great mocked up. I've found you can never have too many of those C-clamps and I buy ones hear and there when I see them.

Love that rolling bulkhead stand too!
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  #86  
Old July 20th, 2014, 07:17 PM
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Quote:
Originally Posted by Uncle Douglas View Post
Brian who's spot weld cutter are you using ?
Beta Utensili, or some old Proto bits.

Quote:
Originally Posted by Don View Post
doing it that way can you get by with spot welding it all or do you needs to TIG/MIG some of the edges? Those YRM panels look great mocked up. I've found you can never have too many of those C-clamps and I buy ones hear and there when I see them.

Love that rolling bulkhead stand too!
We will end up using plug-welds on almost all of the panels - there is one small section just below the door check fittings that will get a small bead applied - simple MIG work. A weldable primer applied to the bulkhead and panels prior to fitting and a good 3M panel sealant into both sides of the panel fittings to help slow the inevitable rot for many years. Not quite back to factory fitted, but better in some ways and a fair compromise in others.
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  #87  
Old July 20th, 2014, 07:25 PM
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Galvanizing warp my bulkheads and the frame mounting points shrunk by ~1". Built this jig today and was surprised how easily it straighten out.
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  #88  
Old July 20th, 2014, 10:10 PM
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Yeah, out of all the threads, articles and first hand accounts of warping bulkheads after galvanizing it was never as hard as people think it will be. Some 2x4's soft mallets and the like will get into postion and its straight as you need it to bolt right up.

Quote:
Originally Posted by lordhelemt View Post
Galvanizing warp my bulkheads and the frame mounting points shrunk by ~1". Built this jig today and was surprised how easily it straighten out.
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  #89  
Old July 22nd, 2014, 10:16 PM
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Finally got around to finishing the bulkhead. Excess zinc on the vent screens removed, all nuts/threads chased, holes re-drilled/filed, and generally cleaned up.

For anyone doing this I recommend sharp drill bits, decent set of tap/dies, and a bottle of mapp gas to re melt excess zinc.

Should be off for paint at the end of the week.
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  #90  
Old July 26th, 2014, 10:03 PM
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  #91  
Old July 26th, 2014, 10:14 PM
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That looks really nice Brian.
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  #92  
Old July 27th, 2014, 01:00 PM
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Quote:
Originally Posted by cbfritz_03 View Post
That looks really nice Brian.
Thanks!

Welding in the inner fender brackets this morning.
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  #93  
Old July 27th, 2014, 01:41 PM
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Are those the prefab wells?

Oh ..duh, sorry. Yes they are. They look really good
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  #94  
Old July 27th, 2014, 10:10 PM
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Quote:
Originally Posted by cbfritz_03 View Post
Are those the prefab wells?

Oh ..duh, sorry. Yes they are. They look really good
Yes, we were the first YRM Metal parts dealer in the US and have been using them with great success for a couple years now.

The standard footwells and inner fender brackets went onto this project, making some custom panels for the other bulkhead this coming week and will be repairing the upper corners using the YRM stuff.
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  #95  
Old July 28th, 2014, 10:54 AM
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Looks really good Brian! Those YRM panels are a treat to work with. I love how they are a little thicker than stock guage. Although I found welding the YRM to the shitty stock Rover metal was a PITA at times.

Wish YRM made a full bulkhead kit - they could ship as panel pieces and the end-user could stitch them together.
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  #96  
Old July 29th, 2014, 10:42 PM
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I've been working on my own bulkhead over the last week. Took a few days to get it free from the vehicle but overall it wasn't too bad.

I then sent it off to soda blasting so I could see what I was dealing with. The worst bits are in the foot wells and right near the opening for the heater. The pillars, top corners and vent openings are pretty great looking other than a small bit on the inside top corners.

Today I did a run down from Ottawa to Ogdensburg NY to pick up some YRM repair panels that I got from Brian at Defenders Northwest they look to be quite good. Thanks for the help Brian!

Next stop was friends metal fabrication shop, we bolted a brace across the bottom both to keep the A-pillars in correct location while we cut out the foot wells, but also as a brace to help with distortion prevention in galvanizing.

Drilling out the spot welds is super fiddly and takes a fair bit of time, but I have gotten through most of it and the foot wells are now out. The YRM panels are pretty darn good shape wise, but some of the openings don't quite line up, however it should be quite easy to fix.

It was quite interesting to cut into the box section of the upper bulkhead, it's not quite what I expected, but you can see for yourself in the pictures below.

Hopefully I can get the repairs rapped up in the next day or two as I would like to have it to galvanizing by the end of the week. Fingers crossed.....
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  #97  
Old July 31st, 2014, 08:12 AM
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What's the general consensus on screen removal before galvanizing?

Is it worth grinding off the spot welds and taking them out? Or is it better just to use a torch and air to blow the zinc out of the holes later?
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  #98  
Old July 31st, 2014, 09:03 AM
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Quote:
Originally Posted by Wilboro View Post
What's the general consensus on screen removal before galvanizing?

Is it worth grinding off the spot welds and taking them out? Or is it better just to use a torch and air to blow the zinc out of the holes later?
i did the torch / air thing and it worked ok. it was a bit messy, however.
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  #99  
Old July 31st, 2014, 06:53 PM
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Quote:
Originally Posted by sonoronos View Post
i did the torch / air thing and it worked ok. it was a bit messy, however.
Ditto.
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  #100  
Old July 31st, 2014, 08:00 PM
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Quote:
Originally Posted by sonoronos View Post
i did the torch / air thing and it worked ok. it was a bit messy, however.
and it probably took him 3 months <wink>
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