I bought a late model Td5 bulkhead since they were available quite cheaply.There are a number differences, but it can be modified to suit the earlier vehicle.
The most obvious difference is the tunnel. This one is for the R380 gearbox.
This is the earlier LT77 tunnel. Here, I have already cleaned up the edges to locate the spot welds ready to be drilled out.
There are more spot welds on the other side.
And there are a couple of mig welds to grind away too.
Here, the tunnel section has been removed from the new bulkhead.
The early tunnel section welded into the late bulkhead.
The early screen vents are narrower than the later ones. So sections of the old bulkhead were welded into the new one.
The wiring passes through the bulkhead in a different position. A suitable hole saw was used to cut the new hole.
Various holes, including the wiring hole, were sealed up. The one of the right has been tacked into place ready for final welding.
The wiper spindle holes were different. So, I chose to weld in some washers to fit the earlier spindles.
The washer was recessed into the hole to make it flush with the surface.
Welded and ground flush.
The various modified areas were primed to protect them while other work was carried out.
First paint! The bulkhead primed.
And top coated. Wow, it's bright!!
Bulkhead loosely fitted. The new wiring harness has already been fed through here.
This is the harness on the reverse side of the bulkhead. I wanted a reliable vehicle and since electrics are the main cause of trouble I bought a new harness from AutoSparks (www.autosparks.co.uk).
The drivers side bracket, even fully adjusted rearwards, left a huge gap to the bulkhead floor. Plenty of adjustment and shimming to do!
The wiper rack was cleaned and regreased. One of the wheelboxes has been replaced. The old one had to be cut off.
Wiper motor and rack installed.
The wheelboxes are just retained through the bulkhead with nuts and washers on the front.
The pedals were stripped to be cleaned and painted. Here is the throttle pedal assembly.
The brake servo was quite rusty, but not perforated. So it was cleaned up ready for paint.
The repainted pedal box and servo being bolted together.
Then the master cylinder was fitted to the servo.
The clutch master cylinder and repainted pedal box.
The clutch master cylinder bolts are difficult to get at. The top one is best done with a spanner on the front and socket on the rear through the access plate.
The bottom bolt is easier the other way round. This applies to when it's in the car too.
The throttle pedal parts painted.
The finished pedal assemblies. Both master cylinders were working before dismantling so they were reused as they were.
The lower dash also forms the heater duct and contains the flaps for directing heat to the footwells. The top face is held in place with self tapping screws.
The underside is insulated to retain heat.
The flap assembly is retained by these leaf springs.
The control cable is attached to the RH end of the flap assembly.
There is a metal shroud where heater feeds through the bulkhead.
The LH end of the dash covers the wiper motor.
It had rust in the botom corner so I cut this out and welded in a new section.
First, the padding had to be removed. It is glued around the edges, so easily removed.
After cutting out the rusty section and welding a repair section in, the dash end was painted. The old padded cover was then replaced.
