Project Ninety: Part Four

Gaining good access to a rusted footwell can take longer than the welding, as Ed Evans explains

Dismantling the rear bodywork reveals an unexpected reason for the Ninety’s history of water leaks

Most elderly Land Rovers have bulkhead footwell corrosion, ranging from minor surface rust to disintegration of the panel. What appears to be relatively insignificant rusting usually turns out to be a bigger job than expected, once the parts have been removed for access, and the rusted areas dug out. But all can be fixed using repair panels, whole or cut to match the damaged area. Of course, repairs will only stay good if the windscreen and bulkhead seals can prevent more water getting in, and ours will be renewed as a matter of course during the rebuild.

Our footwell had already been repaired at some time in its past by applying welded patches from the inside. This is a quick method, but it’s untidy, usually lacks strength, leaves rusty metal on the outside and isn’t waterproof. The only way to do this job properly (apart from the relatively huge task of removing the bulkhead from the vehicle) is to gain proper access by removing the front outer and inner wings, the heater, all interior trim (including seat bases to keep them safe from weld sparks), the floor plates and any incidental parts that might restrict work or be damaged by heat. For us, removing the front wing is all part of the greater plan because it is corroded and needs replacement. So, here we go: Steve Grant makes the weld repairs in the Britpart workshop and we both keep busy removing bodywork and, later, coming in with paint protection when the job has cooled off.