Galvanizing a bulkhead? - Defender Source
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  #1  
Old January 8th, 2013, 06:55 PM
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Galvanizing a bulkhead?

Has anyone done this to their original bulkhead? I'm having mine repaired and debating whether to have it powder-coated with a zinc based primer or galvanized?

I have heard stories about warping and other problems with Galvy.
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  #2  
Old January 8th, 2013, 06:58 PM
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Yes. Zero problems and I would do it again in a heart beat. IMO, the claims of warpage are highly overrated.
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  #3  
Old January 8th, 2013, 07:01 PM
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I did mine, came out nice.

Only downside for me was cleaning out the square holes where the plastic plugs go.
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Old January 8th, 2013, 07:20 PM
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Anyone paint it yet?
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  #5  
Old January 8th, 2013, 07:29 PM
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Bulkhead and all cappings painted, not on the road yet but I have abused them pretty good moving them around and drilling holes and it seems to stick pretty well so far....

http://www.defendersource.com/forum/...t=26346&page=5
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  #6  
Old January 8th, 2013, 07:38 PM
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No paint on the galvy bits, as I love that Rover chrome. Why paint it?
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  #7  
Old January 8th, 2013, 08:52 PM
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I used a carbide tipped dremmel attachment to clean out the square holes. I never considered painting mine so no input there. The flat parts got a little wave to them, but you would not notice if I did not point it out. Way better than powder coating. Just galvanize it!
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  #8  
Old January 8th, 2013, 09:55 PM
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Quote:
Originally Posted by tomaco1 View Post
Anyone paint it yet?
I've always wondered this myself....my understanding is that paint doesn't play nice with galvy. Flakes off/etc if you don't do it right, and to do it right you need to either treat the surface or use some sort of etching primer (which can negate the galvy benefits). Am I off base on this?
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  #9  
Old January 9th, 2013, 01:40 AM
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Dd this on 145/500, no issues aside from extra prep required to get smooth paint. If you're worried, just lightly sandblast the areas to be painted prior to prep.
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  #10  
Old January 9th, 2013, 05:04 AM
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I would not powder coat it for sure. The coating will crack on the outer foot wells, will trap moisture and you will have a rust problem.
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  #11  
Old January 9th, 2013, 07:27 AM
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Repaired mine and had it sandblasted then to the galvanizer's shop. Never painted it as it is the way I like it. It warp a bit, just enough so a body jack was needed to align the bolt (secure it to the frame). Wouldn't do it differently! No rust anymore and it doesn't show that much (air vent are painted the same color as the body and the windshield also. Don't bother powder coating it, just paint or galvanize.
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  #12  
Old January 9th, 2013, 07:58 AM
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I did mine and no warping, just a little time with a soft wheel to get rid of the burrs and I 2K epoxy primed it, painted, then injected the cavity areas 3 times with waxoyl.
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  #13  
Old January 9th, 2013, 10:37 AM
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Mine just came back from the sandblaster and I'm prepping for galvy now. I galvanized then painted my B-pillars and after a year the paint is holding nicely.
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Old January 9th, 2013, 10:55 AM
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Quote:
Originally Posted by broadstone View Post
I did mine and no warping, just a little time with a soft wheel to get rid of the burrs and I 2K epoxy primed it, painted, then injected the cavity areas 3 times with waxoyl.
Why would you have to waxoyl? Doesn't the galvy get in all the cavities?
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Old January 9th, 2013, 10:56 AM
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Quote:
Originally Posted by tomaco1 View Post
I have heard stories about warping and other problems with Galvy.
The only parts that warped slightly on mine were the footwell panels. There's a little bit of waving, but everything else was fine.

It's totally worth it!

------ Follow up post added January 9th, 2013 11:00 AM ------

Quote:
Originally Posted by tomaco1 View Post
Doesn't the galvy get in all the cavities?
Yep, it does. But I'm guessing that people waxoyl in order to prevent further corrosion (since galvanizing doesn't last forever.) I'm personally not a fan of waxoyl, but if the truck will be driven in rust belt winters, having something in there to prevent salt and water from reaching the galv sounds like a good idea.
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  #16  
Old January 9th, 2013, 11:03 AM
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What do folks think about Waxoyl on the outer parts of the footwells after galvy and paint? That's where mine rusted badly. Well that and the posts. And the top. And on the corners.....
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Old January 9th, 2013, 11:06 AM
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Quote:
Originally Posted by tomaco1 View Post
Why would you have to waxoyl? Doesn't the galvy get in all the cavities?
Yes it does but I knew I was using this vehicle in the winter a lot and since rust keeps me awake at night it made me feel better. I figured if there was any seams that the galvy did not fill in the waxoyl would get in there, and any of the harder to blast areas on the inside, though acid dipped may not have the same zinc coverage as the outside.
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  #18  
Old January 9th, 2013, 11:18 AM
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Quote:
Originally Posted by 61rover View Post
What do folks think about Waxoyl on the outer parts of the footwells after galvy and paint? That's where mine rusted badly. Well that and the posts. And the top. And on the corners.....
I put heavy duty undercoat, topped with black waxoyl) on the bottom lower footwells to prevent the stone chips which start the rusting process there (because the stupid inner wheel well does not cover the whole area).
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  #19  
Old January 9th, 2013, 11:19 AM
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Quote:
Originally Posted by evilfij View Post
I put heavy duty undercoat, topped with black waxoyl) on the bottom lower footwells to prevent the stone chips which start the rusting process there (because the stupid inner wheel well does not cover the whole area).
Like that rubberized undercoating you mean?
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  #20  
Old January 9th, 2013, 11:20 AM
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Do it. Check off the one big item that will need repairing in 15 years if you don't.
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