With the Lightweight back in the barn I have been able to crack on with some remedial work on the lower bulkhead and it's mounting. On the passenger side, close to where it mounts to the chassis, the main bulkhead rail had suffered quite badly to corrosion. Initial thought were on how best to repair it, but the more I poked away at it, the less savable it became.
Wanting to get it done right and not have to come back to it again in a few years time, I took the decision to fabricate a new lower section to replace the heavily corroded part. Although the final piece is to be a channel section, I started off with a length of 2" box section as this was what was to hand and could ofcourse be cut down to size. Using the lathe a hole was soon bored close to the bottom to accept the lower mounting point/spreader tube, which was then welded in.
In an attempt to make sure every thing lined up, a basic jig was made up from a piece of Dexian, which seemed to work quite well as it already had all the holes in it I required.
Old and new bulkhead sections side by side
Old piece removed
New piece in, welded and painted
Outer panel also fitted.
Wanting to get it done right and not have to come back to it again in a few years time, I took the decision to fabricate a new lower section to replace the heavily corroded part. Although the final piece is to be a channel section, I started off with a length of 2" box section as this was what was to hand and could ofcourse be cut down to size. Using the lathe a hole was soon bored close to the bottom to accept the lower mounting point/spreader tube, which was then welded in.
In an attempt to make sure every thing lined up, a basic jig was made up from a piece of Dexian, which seemed to work quite well as it already had all the holes in it I required.
Old and new bulkhead sections side by side
Old piece removed
New piece in, welded and painted
Outer panel also fitted.
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