Back to the Bulkhead Section
Please be aware that ECR is now a Defender repair and modification shop only.
We no longer work on Range Rovers, Discos or Series Rovers.
These pages are from work we did in the past and left up for your enjoyment.
Series IIA Bulkhead Repair
This Series IIA bulkhead, or more correctly, what is left of it, has come
to us from Florida for our bulkhead restoration process. The customer cut
away some of the rusted footwells and then had the bulkhead dipped to remove
all the rust and paint. This makes a nice clean surface for us to start
with. The bad news is that because the customer cut away some of the panels
himself in an effort to save money, we need to do some costly fabrication
to get the bulkhead back in shape. There are very specific items that need
to be saved when doing a really rusty bulkhead, and unfortunately some
of the needed pieces are now gone on this bulkhead. The good news is that
we can fabricate them and get the bulkhead back to 100%.
The image above shows the bulkhead top section in our jig. The center section
had too much rust to repair, (you can see it laying on the floor in the
background) as did the door posts and footwells. You can see that all the
rusted areas have been removed and we will now start to build the bulkhead
up again to better than new standards.
For more information on ECR's bulkhead restoration program go
here!
Here you can see the bulkhead taking shape. All the needed repair panels
are in place and the jig arms have been removed so that we can weld the
seams. The jig assures that when the Rover is built up that the bulkhead
will fit the chassis, and the doors will fit the bulkhead. This makes it
so that everything lines up easily, and makes your Rover look great once
it is all together. Next we'll do the door seal lips and make any changes
or upgrades that the customer requires (dual brakes, heater upgrades, whatever)
and get ready to run the bulkhead through our dunk tank system and then
the paint process.
This image shows that the interior side of this bulkhead looks just as
new as the front. If you think it would be nice to have your Series IIA
bulkhead looking this good again with no rust, contact ECR, we can build
one just like it for you.
What sets an ECR bulkhead apart from others that have been repaired in
the truck are the details. The LH red arrow in the image above points to
the correct door seal lip that we fabricate and install on all our bulkheads.
This is needed to retain the factory door seal correctly and it is not
offered on any of the mail door posts that you can buy from any company.
The RH red arrow points to the visible weld that shows on all Series IIA
bulkheads. We duplicate this factory weld exactly by tig welding this area
for a strong, yet original appearance. The details are what makes the difference.
We take steps to not only bring SIIA bulkheads back into shape and get
all the details right, but also to make them last longer. In the image
above you can see that the steel work on this SIIA bulkhead has been completed
and it is now being "dunked" in our dunk tanks. This "top
dunk tank" fully submerges the enclosed upper section of the bulkhead
in heavy duty primer. This coats the inside if the steel panels so that
rust won't be a factor in the future. You can also see that the left and
right door posts have been dunked as well.
Here you can see the fully "dunked" bulkhead. Both door posts
are fully coated inside and out, as is top section around the vent flaps.
This coats all the commonly rusted areas with primer inside and out. The
floors we use in our repairs are galvanized for long life, making this
bulkhead very rust resistant, and once painted in the customer's choice
of Bronze Green, it will probably outlast the rest of the Rover. In the
image above you can also see that we have updated the bulkhead at the customer's
request. We have made the needed changes so that he can install the Rover
power brake pedal box, and have made the needed holes for a Kodiak heater
system. We also filled a number of "extra" holes that people
had drilled over the years to make the bulkhead look as factory correct
as possible.
This image shows the bulkhead after 3 coats of PPG epoxy primer. Before
the primer was laid on the bulkhead was fully media blasted back to white
metal on all the exposed surfaces, and then fully seam sealed and prep'd
for paint in our state of the art spray/ bake booth. This full prime of
all the surfaces, along with the primer that is in the hidden areas from
the "dunking" process means this bulkhead already has a good
shot at lasting a long time, and we haven't even started painting it with
top coat yet!
Do the footwells in your Rover look this good?
Even without paint you can see the detail of our bulkheads. All the factory
holes are in place and clearance drilled for easy assembly. All the non-factory
holes have been filled with metal. The factory look of the footwell, door
post weld and door seal lip are all retained, and no body fillers are used
in our bulkheads. Everything you see is steel. Next we'll bake the primer
and prep the bulkhead for the 3 final layers of Bronze Green paint.
Here you can see the completed project. This SIIA bulkhead is now better
than new, and ready to bolt into the customer's restoration project. The
jig built bulkhead will assure a perfect fit of his body, doors, door seals,
etc. The customer's desired updates to power brakes have all been made
so that his parts will bolt in without hassles, and it has been built with
galvanized parts, dunked, epoxy primed and painted in the customer's color
choice. All this adds up to a long lasting repair for an all too common
Rover problem. It will now be carefully boxed and shipped back to FL.
If you have a rusted bulkhead that needs work, contact ECR.
We can help make your bulkhead better than new... just like this one.
ECR