Restoration

Technical questions and answers
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Cliff4WD
Posts: 56
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat May 04, 2019 1:39 pm

Time for a quick update. I've been experiencing bulkhead fatigue; the last 20% always seem to take 80% of the effort. I'm looking forward to putting the welder away for a while and getting back on the spanners. I moved the spare LT95 nearer my work area in readiness as I think I'll probably be pulling the original out and having a go at overhauling it, we shall see.

Back to the bulkhead then. Top corner first. The YRM panels are only £19 for the pair...

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... so seemed pointless trying to make my own even though I only need a small section...

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I cut the top corner piece and fettled to fit...

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...then it was weldup and grind

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Next, time to fit that strengthening piece I'd made when I started. Drilled it for plug welding and checked for fit...

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...then did the welding

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...and then the cleanup

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Next job, the rusty vent surround. First off, the top rail was a bit out of shape and dented in places. There's damage including old grinder and hammer marks. God only knows what whoever did that thought they were doing. I spent a bit of time with hammer and dolly and put it right.

Started with this section

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I decided to take out the rotted sections and replace with new steel. I did consider trying to source a replacement top rail but that would probably risk more than I gain, the rot is localised and so should be easy enough to deal with in sections, so out with section one

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I then made up a replacement section...

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...and welded n place

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So on it goes, nearly there now.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

User avatar
Cliff4WD
Posts: 56
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat May 11, 2019 6:47 pm

Almost done with bulkhead rust repairs now. I have to admit, finding the motivation to finish it is not easy; the novelty of cutting out rot, making a patch piece, and welding it in and grinding has long since passed. But, the end is now in sight.

Cut out perforated section from top front panel...

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...and tacked in replacement piece...

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...then welded up and cleaned

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Next, sort the LH side of the vent mesh housing

Cut out the rotten section...

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...then fabricate the teplacement piece...


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...weldup and clean

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Next, the bubbling and rot on RH top corner

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Same old story when you reveal what's hiding underneath

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Clean it up and treat...

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...then patch in new steel and clean up

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Now for the RH top corner.

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I was so tempted to just fill in the holes with weld, but that would be silly having done so much already. Just need to keep going and get finished without cutting corners.

Cut out the rot...

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...make a piece for the corner...

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...and weld it in

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Time for beer! I'll finish the last bit next week and then sort out galvanizing.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1459
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse » Sat May 11, 2019 6:53 pm

On the upside, it will never have to be done again.

So glad our roads are not salted, but road builder use lime :x
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

User avatar
Cliff4WD
Posts: 56
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Sat May 11, 2019 7:48 pm

disco2hse wrote:
Sat May 11, 2019 6:53 pm
On the upside, it will never have to be done again.
I certainly hope not :shock:
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

User avatar
Cliff4WD
Posts: 56
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Wed May 15, 2019 6:28 pm

I made an effort and finished off the welding repairs, so finally, can arrange galvanising and move on to the next phase.

Marked section to remove...

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...cut out and cut patch piece to fit...


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...and weldup

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So, after refitting gutter and giving it a good clean, I finally have a complete bulkhead ready for galvanising


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The really soul destroying part of this so far is trying to make good the damage done by whoever butchered the bulkhead in the past. There was a lot more hiding under the paint than was expected. It all looked good to begin with, but then found hammer dents, grinding cuts, deep sanding swirls, hidden rot, heat distortion, etc. Anyway, got there. I have had to leave the dents and dings I can't get behind and will have to fill them when it's painted, I just hope I'm able to make a decent job of it when it comes to it.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

disco2hse
Posts: 1459
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse » Wed May 15, 2019 7:31 pm

It's a work of art and I am sure the builders would be pleased with it.
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5

User avatar
Cliff4WD
Posts: 56
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD » Thu May 23, 2019 8:32 am

Bit the bullet today and sent bulkhead off for galvanising. What's the emoji for apprehension?
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS

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