Is it possible and has anybody replaced a lower bulkhead on MK2 Escort on it's own eg not removing chassis legs/ inner wings. Can it slide in from side or in from cabin.
Is it possible and has anybody replaced a lower bulkhead on MK2 Escort on it's own eg not removing chassis legs/ inner wings. Can it slide in from side or in from cabin.
I’ve not done it, but I am coming to the end of a very extensive shell rebuild. From how the front end is constructed I would think it’s possible but with some cutting and non standard joins. It won’t be easy. The problems I think will be the gear box tunnel. It’s flange fixes on the inside of the bulkhead so you won’t be able to get the bulkhead panel past it. So probably your tunnel will have to come out from just ahead of the gear stick opening. Also the top flange at the outer part of the bulkhead is sandwiched between the rear of the inner wing and the bulkhead top panel. You’d have to cut that flange off your panel and then stitch or seam weld it along this part. That would be an awkward weld and dependent on your equipment and skill level. Also consider that area is prone to rust which will further hinder making a good joint. Although thinking about it you could maybe fix an angled doubler plate up in there, kind of reversing the joint, with plug welds, still an awkward area to access.
Then the bottom section, originally that would be fitted outside/ underneath the main floor panel and there’s a fair over lap I doubt you’d be able to slip the lower edge between the front of the floor panel and the front chassis legs. Welding wise not an issue but reversing that joint would set up an area prone to catch and retain moisture.
So it’s a lot of work with odd cuts and joins on an expensive panel. It might be better to take the time to make up repair sections. Have you got some pictures of why you’re thinking of changing the bulkhead out ?
I follow the bits you are talking about. Shell has the bigger gearbox tunnel so don't think it will be as difficult matching together if I rough precut the new bulkhead. I will just remove my exixting plug welds from the floor to chassis rail as the overlap not that much as quite a bit of the chassis rail joined to the mid section. Would have to relieve the short section of the inner wing to top bulkhead also which will be awkward. I am patient but it took me a long time setting up the alignment and complete front end so not keen removing it. I started my rebuild before they were making the new bulkhead panels (apart from Express which were too dear at the time).
It is a rally shell and although I have done some repairs already to the bulkhead but I feel that the area that is rotten (down the inner wing to bulkhead seam) is just making it all too patchy.
Last edited by Ralyaly; 24-07-2019 at 21:25.
Hi, how did you get one with replacing the bulkhead with chassis rails on? I’m about to try the same, I’m going to take inner wings off anyway but wondered if it’s possible/ easy with chassis rails still on?
thanks
Hi Mk1jack, Your situation is a bit different to the original question. Ralyaly was looking at slipping the bulkhead in with floor, chassis and front wings all in place.
With your inner wings removed your bulkhead will be much easier. You’ll have to carefully remove the spot welds between the floor, bulkhead and chassis rail “sandwich “. The lower part of the bulkhead sits about 10-15cm down between the floor and rails. Once it’s released it should be possible to pull the old bulkhead out from the sandwich. You’ll probably have to open the gap up and do a bit of bending to get the new one back in, but that’s no different to any of the other panels you’re changing.
At the sides there’s a “sandwich “ up the A pillars with the bulkhead (splash panel) being on the outside, there’s also a fairly big panel over lap at the bottom corners, I think that’s the side splash panels (included in your bulkhead) to floor. This area may well have old repair patches to remove anyway. And of course drill out the spot welds on the tunnel to bulkhead flange.
Hope that helps.
If possible please post some pics up as you go, be interesting to see how you get on and it’s really helpful to others
sounds like one of them jobs in your head your piss it then you take look it thinking to your self what do i cut first its making the first move give gary a call at GARY MARTIN MOTORSPORT would be a good one to have a chat with
sideways is the best way to turn a corner
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