If you had your bulkhead out, what else would you do? - Defender Source
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  #1  
Old August 22nd, 2013, 11:12 AM
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Andrew Clarke
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If you had your bulkhead out, what else would you do?

I have my bulkhead out and wings off, as seen in the photo. I only have limited evening/weekend time to work on the truck outdoors, and it absolutely 100% has to be back on the road by October 5 so time is limited.

Here's what I'm planning on doing so far:
- Using new (to me) galvanized 300tdi bulkhead, wiring loom and blade fuses. Replacing old 2.5tdi wiring loom and glass fuses.
- Painting bulkhead
- Spraying Al's HNR on bulkhead and tops and bottoms of floor and transmission tunnel pieces
- Sandblasting the parts of the chassis I can reach, cleaning and painting POR-15 on.
- Replacing lower steering column u-joint.
- New (mostly stainless) nuts/bolts throughout.

I figure I should probably replace any obviously leaking hoses too while I have it all apart. I'd love to fabricate a custom dash but that's completely out of the picture. I also have to redo all my rear wiring during this time, and put all the lights back in as well as hopefully putting my compressor and tank back in too.

Is there anything else that I should either absolutely do, or do if I have time, while I have this all apart?

Thanks,
- Andrew.
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  #2  
Old August 22nd, 2013, 11:19 AM
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brake and fuel lines?
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  #3  
Old August 22nd, 2013, 11:25 AM
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Bill Adams
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I'd say you should hook up a pair of mules, drive it into town and sell fresh baked pies out of the back.
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  #4  
Old August 22nd, 2013, 11:27 AM
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Quote:
Originally Posted by o2batsea View Post
i'd say you should hook up a pair of mules, drive it into town and sell fresh baked pies out of the back.
lmfao!
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Old August 22nd, 2013, 11:30 AM
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My recommendation: Do not use Al's HNR or any other bed liner for that matter on your truck.

The rest of it sounds ok.

Wiring took me about 3 months total to do a full custom rewire. If you have 1.5 months, I recommend minimizing the electrical work to plug-and-play and/or fixes.
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Old August 22nd, 2013, 11:38 AM
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Where you are you are 75% of the way to getting the frame out and 90% of the way to having the t-pieces out. I would do it right and take the frame off and the t-pieces out and have them all galvanized. At the very least I would do the t-pieces. They rot badly.
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Old August 22nd, 2013, 11:43 AM
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Quote:
Originally Posted by o2batsea View Post
I'd say you should hook up a pair of mules, drive it into town and sell fresh baked pies out of the back.
Well, it is Mennonite country, so this sort of image is actually pretty common:



A lot of the wagons are repurposed truck frames, so all I'd really have to do is paint all the blue black.

I'll go over the brake and fuel lines and replace anything that looks suspect. My glass fuse panel is already pretty hosed, with some of them not working any more, so I think the 300tdi harness and fuse panel is probably my easiest option. The rear wiring is already taken apart, so I have to put it all back together at this point anyway.

Regarding bed liner, well it's already too late for that: http://www.clarke.ca/post.cfm/land-rover-bed-liner . However, Al's HNR is not Al's Liner. It's "Heat & Noise Reducer". I haven't load tested the U-Pol Raptor I just sprayed in the back, but the fingernail test is making me a bit concerned that it might not be as durable as I was hoping it would be. I went that route though instead of Line-X as they wanted $675 to do the bed in blue. Plus, they said it would be close to $1000 for them to coat my roll cage, and they'd sandblast off most/all the galvanizing first in order to do it. I decided that was dumb and too much money anyway, and figured I'd do it myself. Time will tell.

------ Follow up post added August 22nd, 2013 11:46 AM ------

Quote:
Originally Posted by evilfij View Post
Where you are you are 75% of the way to getting the frame out and 90% of the way to having the t-pieces out. I would do it right and take the frame off and the t-pieces out and have them all galvanized. At the very least I would do the t-pieces. They rot badly.
I decided against a frame-off, as I have a solid frame. The outriggers are good and solid in my case. The rear crossmember was a mess and I had that replaced last year, and my bulkhead is a sorry disaster, which is why it's being replaced now. Thanks for the idea.
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Old August 22nd, 2013, 11:54 AM
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Don't paint the galvy bulkhead!
Don't forget to slather bolts with anti-sieze.
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Old August 22nd, 2013, 11:59 AM
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Quote:
Originally Posted by grnrvrs View Post
Don't paint the galvy bulkhead!
Don't forget to slather bolts with anti-sieze.
I don't want the galvanizing to show in the visible parts of the bulkhead, so I'm painting it. I painted my galvanized bumper about 6 years ago, and it's just now starting to wear through a tiny bit on the bumper edges where I climb up and down to get on the roof. With proper prep, it's fine to paint a galvanized surface.
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Old August 22nd, 2013, 12:05 PM
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If you can find a dry ice blaster, do that instead of sand blasting. It's so messy and it gets in everything. No clean up with dry ice.
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Old August 22nd, 2013, 12:12 PM
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Quote:
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If you can find a dry ice blaster, do that instead of sand blasting. It's so messy and it gets in everything. No clean up with dry ice.
I've never even heard of that. Thanks for the tip. I have a sandblaster, and yes it does get everywhere.
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Old August 22nd, 2013, 12:15 PM
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At least do the T pieces.
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