Looking for guidance on Bulkhead replacement - Defender Source
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  #1  
Old September 29th, 2014, 12:50 PM
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John Crouse
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Looking for guidance on Bulkhead replacement

My bulkhead is disintegrating before my eyes and I need to move on a fix. I have a real NAS D110 bulkhead that has been galvanized and painted ready to go. Here's my question. I would of course prefer to do bulkhead and frame together but can't swing that at the moment. I need someone to pull the old bulkhead, move all the ancillaries over to the new one and reinstall. I can do some disassembly to prepare. I've done this on my Series, but my D110 won't fit in my garage so doing it myself is not an option.

What is a fair cost to have someone do this? I just don't have the facilities to do it myself.
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  #2  
Old December 9th, 2014, 12:23 PM
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John Crouse
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Anyone? I need to get moving on this.
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  #3  
Old December 9th, 2014, 12:49 PM
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WAG $3k.
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  #4  
Old December 9th, 2014, 01:44 PM
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John Crouse
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That's pure brilliance.
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Old December 9th, 2014, 01:59 PM
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You could even roll it in on four wheels without tires if you had to. Budget for new cage mounts under the front wings. If the bulkhead is shot, likely they are too.
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Old December 9th, 2014, 03:22 PM
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JP,

If it could be done in a weekend I have 8 foot garage doors and could make space.

Maybe arrange a work day with a few people?
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Old December 9th, 2014, 04:20 PM
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Quote:
Originally Posted by dave_lucas View Post
If it could be done in a weekend I have 8 foot garage doors and could make space.

Maybe arrange a work day with a few people?
I think it could be done in two 14 hour non-stop days - assuming you have every single part you need. Therein lies the rub. A freshly painted and galved bulkhead requires a whole bunch of small plastic nuts to fully prep. You will need a large supply of m4, m6, and m8 fasteners. You will also need several gallons of simple green, a pressure washer, and several nylon scrub brushes.

I lifted the roof of my 90 into place myself. It was very difficult due to its bulk. You will definitely need a second person (at least) to remove the roof of a 110. Once the roof is off, then the next worst problem is the pozi bolts holding the windshield hinges onto the bulkhead. Usually these are seized due to corrosion and you cannot get them off without a #4 pozi bit and an impact driver. Other huge pains in the butt are the bolts holding the wings to the bulkhead. IIRC there is no way to remove the bulkhead without removing the front wings and bonnet.

Next are all the dash components and wiring, which are also a pain in the butt.

Now you know why it's expensive...I spent the better part of two months ordering lots of little parts to fully prep my bulkhead.
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  #8  
Old December 9th, 2014, 04:32 PM
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John Crouse
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Quote:
Originally Posted by dave_lucas View Post
JP,

If it could be done in a weekend I have 8 foot garage doors and could make space.

Maybe arrange a work day with a few people?
Dave I would love to do that if we could get some help. I can do a lot of pre-work and remove as much as I can while still being able to drive it to your house.

Let's get a beer and talk about it. I'll talk to Russell Wilson as well. He usually has good ideas.

J.P.
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  #9  
Old December 9th, 2014, 04:40 PM
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I highly suggest talking to Les at RN and ordering everything needed. Fit the rivnuts and clips and screw holders in advance.
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  #10  
Old December 9th, 2014, 04:44 PM
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John Crouse
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Thanks Ron. I seem to remember a list of bits you posted. (I think it was you). I'll reach out to Les. I have new hardware for the hinges and some of the others already. Just need to figure out the delta.
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  #11  
Old December 9th, 2014, 05:11 PM
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no need to remove the roof
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  #12  
Old December 9th, 2014, 07:55 PM
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Sending you a PM JP
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