Replacing a bulkhead
Pros and cons and how to install one
THERE are two major elements of a Land Rover that are made of steel and that will rust. One of these is the chassis and it is fairly commonplace now to replace an old rusty chassis that may have been welded and repaired many times already during its life with a brand-new galvanised chassis to prolong the life of the Land Rover. The other major steel component that rusts in obvious places and in unseen areas, is the bulkhead. Total replacement of the bulkhead is not so common, partly because there are many excellent repair sections available, and also because replacement is a major job. It is arguably a more involved job than replacing the chassis.
The Land Rover bulkhead is essentially the heart of the vehicle. Almost every single system goes through it or is attached to it in some way or another: electrical, steering, brakes, clutch, heater, wipers – the list goes on. In addition, the doors, floor, windscreen, front wings and roof are all in some way attached to it or impact upon it – and most need to be removed to replace the bulkhead.
In the old days, a rusty chassis and/or bulkhead could spell the end of a Land Rover and it would be dismantled for spares. These days most are being saved and given a new lease of life by fitting a new chassis and bulkhead, usually galvanised, making them able to last at least as long again, as the life they’ve already had.
While a bulkhead change is an involved job that requires lots of time and patience, the good news is there is not really any specialised equipment needed to carry out the procedure. It can be done on the workshop floor or even the driveway (as long as you cover it overnight and put your tools away). And the manual handling by two persons is just about all of the specialised lifting that will be needed.
Clearly, a replacement bulkhead will need to be sourced, although availability is improving with more outfits producing refurbished or new products. A number of associated replacement parts will also be required, which adds to the cost. Alternatively, the original bulkhead can be removed, sand blasted and repaired if it is not too far gone and you have access to the tools and skills to do this.