Having now completed my bulkhead swap on my old 110, I thought I'd post some thoughts and info for anybody else thining of doing it themselves.
First thing I'd say is buy a new one, correct for your Landy. Yes, new bulkheads are very expensive but I went for a reconditioned one which was then galvanised.....
I checked with the supplier that all holes would be correct for a 1985 110... He said yes..... they were not. I spent a weekend altering the new bulkhead, copying measurements of fixings and holes from the old bulkhead that I had already removed.
Also, the galvanising was a bit messy, the paint colour was wrong and it took a lot longer to be ready for collection than originally quoted. I'll not post this suppliers name on here but PM me if you want to know. They're not a million miles from me... But it's not Strathearn.
Anyway, aside from tinkering with the 'new' BH, I took ages to do the job because I took the opportunity to fettle with a few things as I went. I rewired both wings whilst they were off, I chopped each wings wiring loom near bulkhead end and put a multiplug in. Handy if I ever need to remove a wing again and saves messing disconnecting more than is needed.
I ran new and separate earth wires to a common earth point on the BH from both wings, I aslo ran new, chunky, battery earth cables between the battery Neg / Chassis / Gearbox and Bulkhead. A Local auto electricians made them up to my spec for length and terminal types.
I bought all new fixings, especially a big selection of Stainless self tappers, penny washers, stainless normal capscrews and button head capscrews. Galvanised M8 nuts and bolts. (Orbital Fastners Ltd are excellent suppliers).
Any Land Rover specific fixings were from my supplier for all other parts, Island 4x4.
Buy a Rivnut tool and selection of rivnuts. Seriously, I wish I'd bought one years ago, so handy for all sorts of bits.
If you're thinking of replacing your front springs and turrets do it now whilst the wings are off. Did mine a few months back, should've waited, so much more room!
I didn't disconnect brake pipes at the servo. I did disconnect clutch pipe and I did drain coolant, not fully but just out of the radiator which lessens the amount spilt when removing the heater blower unit.
Wiring wise, MARK EVERYTHING FIRST! And take photos. Of everything! I unplugged all the connectors just inside the engine bay, and as I've said, cut the wing looms, and pulled it all back through inside once all the dash was gone. The wiring behind the binnacle and steering column is a bit messy and I have an immobiliser which complicates things, but just be careful and keep note of what you unplug. Whilst I had all the loom out I cleaned all the crimps that looked a bit tarnished.
As the bulkhead was for a newer landy than mine I had to create fixing holes for the original wiper motor, and the new BH had different holes for the wiper boxes and washer jet, so new ones were needed.
I did all the job myself apart from the actual removal and dropping in of the new BH, where my wife helped lift the old out and new one in. I didn't remove the windscreen. I did, however, need to chop the sill rails and rejoin them afterwards to get enough play for the new BH to drop in to place. It will be easier if you do remove the windscreen but I couldn't be f***ed and I'll be replacing the sills at some point anyway.
It was a bit fiddly and frustrating at times, but arn't all Landy jobs, but it's done now, all working and will hopefully last a long time.
Below is a list of everything I bought from Island 4X4 for your information. And just a reminder that I have a 1985 110 and the new BH was for (I think) a TD5, so it's a right mish mash of bits.
Cheers, Mike.
1 x Door Bolt Kit S/S (2-Door) DA1132 (DA1132)
2 x Wiper Wheel Box 83-02 (Britpart OEM) PRC8495G (PRC8495G) INCORRECT for new bulkhead.
1 x Seal Heater Duct RHD 83-06 (Britpart) STC952 (STC952)
1 x Seal (Genuine) MRC8378 (MRC8378LR)
1 x SEAL PCZ500060 (PCZ500060)
1 x PIPE CLIP X10 NRC9246 (NRC9246-QTY)
2 x Vent Seal Bulkhead Rubber Series 3 & 90/110 83-92 (Britpart) MUC4299 (MUC4299) INCORRECT for new bulkhead.
1 x Seal Bulkhead To Windscreen 90/110 (Britpart) FAJ100020 LR055345 (LR055345)
2 x Bulkhead To Outrigger Bolt (Britpart) AYG500080 MRC9420 (AYG500080)
4 x SPACER-HINGE BDC710040 (BDC710040) INCORRECT for older doors.
1 x Rivet x 100 (Britpart) AFU1075X (AFU1075X)
10 x Wing To Bulkhead Bolt (Britpart) AM605061 (AM605061)
1 x NUT X10 AK616011 (AK616011-QTY)
3 x Nut Square Plastic Insert X10 (Britpart) CZA4705L (CZA4705L)
2 x NUT LOCKUT X10 RTC3745 (RTC3745-QTY)
2 x CABLE TIE X10 AAU3686 (AAU3686-QTY)
2 x LOCKUT NUT X10 RTC3748 (RTC3748-QTY) Not exactly right. Correct Ones bought on ebay.
2 x Washer Jet Front Early (Britpart) PRC2437 (PRC2437) = £4.16 INCORRECT for new bulkhead
4 x Steering Lock Shear Bolts QRH100030 51K4001L (QRH100030)
1 x SPIRE NUT X10 53K3039L (53K3039L-QTY)
1 x SPIRE NUT X10 AK606031 (AK606031-QTY) 2 x CABLE CLIP 13H7343L (13H7343L)
6 x Seal Floor Plate 1.6m (OEM) MRC8626 (MRC8626) Just very handy to have for other bits.
1 x Dash Facia Trim 90/110 LHD 83-01 (Genuine) MTC6167 AWR5987 (AWR5987LR)
1 x Door Seal Front RH (Britpart) MWC1080 ALR4936 CFE102981 CFE102720 LR024954 LR044307
1 x Door Seal Front LH 90/110 CFE102991 ALR4937 CFE102730 MWC1081 LR024955 LR044308
2 x Stay (Britpart) ASU710130 MRC5153 (ASU710130)
2 x BOLT PLATE MRC5765 (MRC5765)
1 x Windscreen Rubber 90/110 (Britpart) MUC3733 CPE500010 CPE500020 LR056278 (MUC3733)
1 x Gearbox Tunnel Diaphragm (Genuine) RTC6826 (RTC6826)
1 x TUBE DUCT MRC8642 (MRC8642LR)
1 x Mudflap Brackets Pair 90/110 Galvanised (Britpart) DA1188 (DA1188)
1 x Mudflap Front 90/110 Pair (Britpart) RTC4685 (RTC4685)
1 x Mudflap Rear 110 LH With Bracket (Bearmach) CAT500350PMA LR055334 (No Logo)
1 x Mudflap Rear 110 RH With Bracket (Bearmach) CAT500340PMA LR032965 LR055330 (No Logo)
4 x Door Hinge To Bulkhead Shim Gasket (Britpart) 347369 (347369)
2 x Bonnet Bush 346849 (346849)
1 x Check Strap Channel RHF (Britpart) MWC5018 (MWC5018)
1 x Check Strap Channel LHF (Britpart) MWC5019 (MWC5019)
1 x PLUG X5 MWC2309 (MWC2309-QTY) Incorrect for new bulkhead
1 x Wiper Spindle Seal 2003 On (Genuine) DKK500010 x 10 (DKK500010x10)
2 x Wiper Wheel Box 02- (OEM) DKU500010G (DKU500010G)
2 x Windscreen Hinge Gasket (Bottom) MXC9982 (MXC9982)
1 x Seal Bulkhead To Bonnet (Britpart) LR053843 CJE100770 MWC2567 (LR053843)
2 x Vent Seal Bulkhead Foam 92 On (Britpart) ALR2220 JAE000030 (JAE000030)
2 x Wiper Arm Front RHD 2002 On (Britpart) DKB000060PMD DKB000061PMD (DKB000061PMD)
1 x Washer Jet Front 86 On (Britpart) AMR3025 LR061677 LR034309 (AMR3025)
4 x Wiper Spindle Blank 90/110/130 02 On (Britpart) LR014315 (LR014315G)
Also various new bolts & screws.
