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#Post#: 79423--------------------------------------------------
Replacing bulkhead outrigger
DIR By: 85KB64
Date: November 11, 2013, 1:37 pm
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My Series 3's driver's side bulkhead outrigger needs replacing
before long, but I've not done one before and wondered, do I
need to do anything to support the bulkhead before chopping out
the outrigger? It's a hard top so I'm assuming the rest of the
body will give some rigidity to the bulkhead even when the
outrigger is removed, but I'd appreciate any tips just in
case...
Cheers!
#Post#: 79456--------------------------------------------------
Re: Replacing bulkhead outrigger
DIR By: Peter de Dawg
Date: November 11, 2013, 4:55 pm
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You basically need to ensure the driver's door still lines up
square ( and closes etc ! ) in both orientations ..I've had
success improvising a jack under the 'foot' of the b/head door
pillar to line everything up prior to tacking the rigger in
place and welding ( a bit of fine adjustment with a hammer is
always traditional here too ;D )
#Post#: 79567--------------------------------------------------
Re: Replacing bulkhead outrigger
DIR By: NoelC
Date: November 13, 2013, 1:59 pm
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Is the bulkhead sound? If so, the bracket that bolts to the
footwell and chassis should prevent it moving. I've done a few
and not had anything move out of line, but the bulkheads were
all solid. I'd guess a crunchy teabag of a footwell might not
help the cause.
#Post#: 79680--------------------------------------------------
Re: Replacing bulkhead outrigger
DIR By: 85KB64
Date: November 14, 2013, 2:36 pm
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Thanks guys. The bulkhead is sound, only a few spots of rust but
nothing structural. The outrigger that bolts to the bulkhead
(first one back from the front wheel) is totally done for - it
had filled up with mud so rotted out from underneath. The top's
sound but the sides are on their way out so I was going to be
lazy and chop the whole thing off, buy an off-the-shelf
outrigger and weld it on, rather than trying to repair the
existing one.
#Post#: 79812--------------------------------------------------
Re: Replacing bulkhead outrigger
DIR By: guest13
Date: November 16, 2013, 10:25 am
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You dont need to do anything,
Unless you have structural issues with the bulkhead, the other
mounts are sufficient that nothing will go anywhere
If things do move, you have rot elsewhere that is weakening
things
DON'T slap it on with a big backing plate over the top of the
chassis, that is a bodge, and will help the chassis rot out
behind it - as well as being quite a bit weaker than the
original
Cut of the old one, check the chassis rail - if its got holes
(other than the drain hole) cut that rot out and replace with
good metal, then fit the outrigger, welded to the chassis rails
#Post#: 79951--------------------------------------------------
Re: Replacing bulkhead outrigger
DIR By: estwdjhn
Date: November 17, 2013, 5:09 pm
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5988 pretty much has it ^^^^
A couple of further thoughts - buy a replacement bolt for the
outrigger/bulkhead foot connection. Murphys law will otherwise
apply, and the old one will be rusted solid.
If the chassis rail has rotted out behind the outrigger, I
sometimes leave the backing plate on the outrigger, and cut a
hole in the chassis rail to fit it into before butt welding
round. A lot depends how well the outrigger fits up
dimensionally. (IIRC, 109" outriggers were originally slightly
deeper than 88" outriggers as a 109" has deeper main chassis
rails - however all the replacement outriggers are 88" type - it
doesn't really matter in practical terms, but is worth knowing
when working out why they don't look quite the same).
If you want a really nasty job, do the same outrigger on a 90
for someone >mgun>
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