Advice please on bulkhead section ?

[B1N9S]

Hi guys, I need to repair a section of bulkhead on my BMW 02 project. I have removed the scuttle for access. But the area is quite complex, so not sure where to start really.

I bought a sheet of Zintec, to fab some new metal, but I have limited shaping tools and experience. Any advice ? Would I be better off getting a pro in for this area ?

It is basically, the area below the pedal box and a long section where the scuttle would join the bulkhead. The area under the original spot welded area has rotted through in most areas. Also a small bit around the heater housing.

Cheers.

 

[pedrobedro]

Get some card and make templates first then see if you can transfer them to metal. It doesn't need to be too thick the shape gives it rigidity.

 

[B1N9S]

Thanks Pedro. Would you try and make it as a whole section, or in 2 or 3 different pieces ?

 

[pedrobedro]

I would cut out as little of the original as possible just get back to good metal. I make templates then transfer to metal then draw round them to cut out so I get a good fit when possible.

 

[Shedendman]

its in a place that wont be seen after the floor carpets are on etc,do it in patches if that feels ok for you, long as its strong,whos gonna know?

 

[B1N9S]

its in a place that wont be seen after the floor carpets are on etc,do it in patches if that feels ok for you, long as its strong,whos gonna know?

Some of it will be visible from the engine bay. But I know what you mean. I'll see if I can get some sensible sections CAD'd. (Cardboard Aided Designed !)

 

[cocker]

Sounds like you've been watching project binky .

 

[mike 109444]

Think you are going to need to remove that pedal bracket as the rot goes under it. Keep the rotten plate under it after cutting out as it will allow you to transfer it's position onto new metal. I would say the most tricky bit will be the area that goes under the gearbox tunnel as it ten goes into a seam

 

[B1N9S]

Sounds like you've been watching project binky .

If you mean that guy who transferred the Celica into a Mini......Yes mate. Does it show !! haha.

Think you are going to need to remove that pedal bracket as the rot goes under it. Keep the rotten plate under it after cutting out as it will allow you to transfer it's position onto new metal. I would say the most tricky bit will be the area that goes under the gearbox tunnel as it ten goes into a seam

Thanks Mike. I was hoping to avoid that, but I reckon you might be right.

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