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  #121  
Old November 17th, 2014, 09:23 PM
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Wasn't sure if I should have started a new thread but thought what I am doing next is small enough and applies to the thread.

So - part of the bulkhead fix for me was going from RHD to LHD. A main piece of the conversion that is different is the lower dash. LHD lower dash pieces aren't cheap. Uncle Doug mentioned in an old post how a RHD lower can be modded to work. I am going to give that a go even tho my RHD lower dash looks like it is ready for the trash.

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First patch panel - still need to finish welding
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Cut off of LH drivers side - this is so the steering column can fit - the lines are already on the RHD lower dash. The cut out section will be used to patch the old right hand cut out.
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  #122  
Old November 18th, 2014, 07:02 AM
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And to think I threw one of these out a few years ago.
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  #123  
Old November 18th, 2014, 08:20 AM
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Don- an easy/elegant way to cover it would be with this when you are done. They will make it for lhd for the same price. They also do the top pad and wiper cover. Stitching can be in any color, I just posted black. Check out their # of items sold and feedback rating.

http://www.ebay.co.uk/itm/BLACK-STIT...item5afc72031a
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  #124  
Old November 18th, 2014, 09:33 AM
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Quote:
Originally Posted by TDI Guy View Post
And to think I threw one of these out a few years ago.
Yikes - Have you seen how much these are going for now?! They are getting more expensive than bulkheads. There really is not much to them either.

------ Follow up post added November 18th, 2014 09:34 AM ------

Quote:
Originally Posted by Uncle Douglas View Post
Don- an easy/elegant way to cover it would be with this when you are done. They will make it for lhd for the same price. They also do the top pad and wiper cover. Stitching can be in any color, I just posted black. Check out their # of items sold and feedback rating.

http://www.ebay.co.uk/itm/BLACK-STIT...item5afc72031a
Thanks Doug! I will get in touch with them and see if they can do a LHD one. Should make it look really good.
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  #125  
Old December 2nd, 2014, 09:54 PM
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A few pics of the lower I've been patching up. Pretty close to finishing the patch work. Then I need to learn some metal shaping skills and I might just have GSD powder it. If anyone sees anything I missed let me know.

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  #126  
Old December 2nd, 2014, 09:57 PM
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Looks great, always wanted to do that. (Well, not REALLY)

I would suggest a proper job of POR 15 or galvie over powder coating.
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  #127  
Old December 2nd, 2014, 10:00 PM
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are you going to weld in patches where the rhd switches and column cut were ?
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  #128  
Old December 2nd, 2014, 10:24 PM
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Quote:
Originally Posted by Ren Ching View Post
Looks great, always wanted to do that. (Well, not REALLY) I would suggest a proper job of POR 15 or galvie over powder coating.
No - you do not want to do it! Actually - a RHD lower that had good metal and was straight would be pretty easy. Most of the work I've done is fixing rotten sections. But I feel like I've gotten better working with sheet.

A galvy bath would have this looking like Swiss cheese and twisted to hell. I'll talk to my powder guy. Mane have him sand blast it and I'll POR-15 it. So many little nooks tho. But it is an item that could see moisture.

------ Follow up post added December 2nd, 2014 10:31 PM ------

Quote:
Originally Posted by Uncle Douglas View Post
are you going to weld in patches where the rhd switches and column cut were ?
Yup - already started! Going to use the plate cut from the left side and then a piece of sheet behind it to stiffen it up.

And I need to make a plate for the separator (piece that separates window vents and lower vent zone). I know there is a LHD specific one but it's over a $100 in the UK and can't imagine how much shipping it would be! I think I can make a piece out of sheet in an hour or less - depending on how trick I want to go.
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  #129  
Old December 2nd, 2014, 11:54 PM
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hell of a way to spend your birthday
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  #130  
Old December 5th, 2014, 12:21 AM
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Quote:
Originally Posted by Uncle Douglas View Post
hell of a way to spend your birthday
Not a bad way at all actually. I really enjoy working with metal and welding so felt good to spend some "guilt free" time doing it vs other household things I was suppose to do

I think I am mostly done. If this was an exterior body panel I would put more time in but it will be covered so I figured why kill myself even more. It is mostly straight and most importantly feels really solid. Clamped it to the bulkhead and the holes line up - can't wait to paint it, get it covered and final install it.

As a side note the 2 main riv-nuts are M5 according to the parts catalogue. Any reason not to bump up to m6?

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  #131  
Old December 7th, 2014, 04:43 AM
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Don I talked with the sales guys at Voigt & Schweitzer LLC in Taunton recently; I forgot pricing but it was reasonable
Yeah, about V&S Taunton. Probably the worst galvanizing shop ever. They pretty much damage everything. I watched them back a forklift into a pair of bulkheads I had and then push them across the lot into someone else's pile. Salvaged them but was expensive and V&S didn't compensate at all. Up until then I had used them exclusively. They are the cheapest though.
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new expansion complete. Not only are we the only Rover shop in Eliot Maine...now we're also the biggest.

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  #132  
Old December 7th, 2014, 05:41 AM
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RN stocks M5. I admit I paid RN prices for all my rivnuts genuine of course on the bulkhead and certainly felt it worth it.
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  #133  
Old December 7th, 2014, 06:13 AM
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You mean this M5?
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  #134  
Old December 7th, 2014, 06:26 AM
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You mean this M5?
LOL. No, but I can thank Les for suggesting I buy the M5 bolt too.
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  #135  
Old December 7th, 2014, 08:37 AM
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RN stocks M5. I admit I paid RN prices for all my rivnuts genuine of course on the bulkhead and certainly felt it worth it.
I have M5 rivnuts from McMaster. Was going to use them but could easily order the Genuines if that much better. Is the genuine M5 bolt for it flanged? I was just going to a use stainless with lock washer the a fender washer.
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  #136  
Old December 13th, 2014, 06:09 PM
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So the lower dash has the top flat piece of sheet that once screwed on makes the compete piece a duct similar to what you would find at home. There is a LHD specific piece but I took the RHD piece and cut the one side and then butt welded some sheet onto the other side where the RHD steering column was. I will use dynamat as a sealer as I can't think of anything off the top of my head that would work and I have some pieces if it laying around.

I am going to bring to the powder coaters this week for drop off. Will see if he has anything a little more water resistant than straight powder for the main piece. Now I just need to order that leather cover from the UK and it should all go on in the next month.

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  #137  
Old December 13th, 2014, 10:46 PM
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I just started to repair one of my bulkheads. Removing the old foot wells is more work than I thought. There are too many spot welds to drill out. I have no idea how anyone could do this with the bulkhead still on the D. If I have time tomorrow I'll clean up the old material and tack in the new metal. Then i'll do it all again. I hope to get everything off to galvanizing early next month.
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  #138  
Old December 14th, 2014, 10:03 AM
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Looks good Paul.

One mistake I did was not cutting enough metal out of the bulkhead. Not sure if you are using the YRM panels but the YRM metal seemed so much better than the Rover steel. Welding YRM to YRM panels was nice, YRM to old Rover stuff was not. I would add a straight edge piece of channel or angle to those bottom post mounts to keep things straight. I didn't and mine was a little twisty.

Are you keeping the vents closed or converting to open?
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  #139  
Old December 14th, 2014, 10:21 AM
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Quote:
Originally Posted by don View Post
Looks good Paul.

One mistake I did was not cutting enough metal out of the bulkhead. Not sure if you are using the YRM panels but the YRM metal seemed so much better than the Rover steel. Welding YRM to YRM panels was nice, YRM to old Rover stuff was not. I would add a straight edge piece of channel or angle to those bottom post mounts to keep things straight. I didn't and mine was a little twisty.

Are you keeping the vents closed or converting to open?
This is a NAS110 bulkhead so no vents.

I was looking at what you removed did you cut out the floors or remove the pans by drilling out the spots? on closer inspection it looks like you cut them them out. I drilled out the spot welds so I was able to remove the entire panel. Yes,i'm using the yrm stuff. I dry fit one last night and it was close to fitting perfectly but there are a few things i need to grind down first before i'll know for sure.

Of all the stuff i've down this is by far the worse job.Not difficult but tedious and a general pain in the ass.
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  #140  
Old December 14th, 2014, 10:40 AM
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Looking good.

Since you have kept the inner "wings" and the pillars you shouldn't have this problem, but I'll mention that when I did this on my series bulkhead I seemed to have lost about 1/2" of depth in the footwells. I thought I was being pretty careful with measurements to make sure everything kept straight and square but missed this. Possibly the crappy pattern parts I was using, but most likely user error. I also replaces the pillars though.

This is not for you current project is it?
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