Bulkhead Replacement help

Has anyone done a front bulkhead replacement on a 1980 Series 2 tintop??

How easy is it to do?

Did you need to take the engine out?

Where do we get the bits/bulkhead panel from?

Any help gratefully received  

Entire bulkhead shouldn't be that hard for a competant welder, more a case of a lot of stripping - you need to replace the whole thing? Would definetely be best to take out engine and steering rack plus any other attached items such as fuel lines. You will also need to remove dashboard, carpet, underlay, trim, fusebox, pedals… basically anything in the way and/or burnable.

Cheers

yes - it's the horizontal panel that the wiper motor mounts to that needs replacing along with the part where the accelerator cable comes through as it has pulled through!

Any idea where I can get the bits?
Cheers

Oh yeah… as far as I know you won't get new panels for those areas. Best bet are decent panels cut from a donor shell, try crazyquiff!

Cheers

Debs

Where the accelerator cable has pulled through you can get a smallish preformed piece of sheet metal that actually only needs glueing to the bulkhead as all the force applied by the cable tries to push this plate against the bulhead (it is fixed to the engine bay side).  I have often seen these pieces on evil-bay.  As far as where the wiper motor mounts, I would say that any competent body shop should be able to mig/tig weld a repair piece into your existing bulkhead.  Methinks replacing the whole bulkhead would ott.

If not on evil bay for the clutch cable repair, maybe Crazyquiff:

http://www.golfmk1.co.uk

 has a suitable piece

or Hadrian:

http://www.carpanels.co.uk

Good Hunting from up Jessun Herrod way

Cheers

Super

What like this bit third piece down?

http://www.vwgolfmk1.o…s=0&postorder=asc&start=0

yradave said

What like this bit third piece down?

http://www.vwgolfmk1.o…s=0&postorder=asc&start=0

No it is the large panel underneath the bonnet and the plastic tray that is in the engine bay. It is directly above the pedal assembly. That piece is the lower mount for the windscreen isn't it?

this one? i know its a bit OTT but i like the pic

ideally you want to get an entire bulkhead from an auto doner car as they didnt have the hole cut out for the clutch cable, so dont have the rot,you would be hard pressed to find a decent bulkhead from a non auto as they all rot in the same place, all mine have a repair plate over that section, apart from the auto  :roll:

opentopvw said

ideally you want to get an entire bulkhead from an auto doner car as they didnt have the hole cut out for the clutch cable, so dont have the rot,you would be hard pressed to find a decent bulkhead from a non auto as they all rot in the same place, all mine have a repair plate over that section, apart from the auto  :roll:

the auto version does have a hole for the clutch cable but on mine there's a gromet in it!!

i stand corrected, the auto's dont have a rotted hole ( unlike the ex ) :twisted:

foxymk1 said

this one? i know its a bit OTT but i like the pic

That's the one - I saw the pic and just thought holy smeg - mega work ahead!

opentopvw said

ideally you want to get an entire bulkhead from an auto doner car as they didnt have the hole cut out for the clutch cable, so dont have the rot,you would be hard pressed to find a decent bulkhead from a non auto as they all rot in the same place, all mine have a repair plate over that section, apart from the auto  :roll:

So what's the best place to get that from? Is there a good dismantler that volks would recommend? :?

As already mentioned try crazyquiff at http://www.golfmk1.co.uk/ to source donor bulkhead and scuttle tray (where wipers mount). The bulkhead can rot around the clutch cable aperture, but not common for them to go elsewhere unless the car is a basketcase. It might be a case of finding a decent bulkhead that needs a repair to the clutch cable aperture, in which case get the bulkhead and the aforementioned clutch cable repair panel (about 10cmx10cm) from GSF or Euro Car Parts. Weld the clutch panel onto bulkhead panel, don't use sticky backing.

Cheers