Rear bulkhead - nearside - Part 2

Things are looking a little better in the bulkhead/rear floor area, despite a worrying amount of metal coming out. This is one of those jobs where you just have to think "it's gotta go..." and cut away. For the uninitiated, the area is at the end of the floor, behind the rear passenger seat.

The old repair plates have now been cut out and actually it is not looking as bad as I thought it would. The chassis rails underneath are pretty sound, so thoughts will soon turn to fabricating a new bulkhead repair in this area. I did actually put some new metal in today, as one of the edges of the chassis rails was rather thin. Plus, I made up a panel for the vertical section of the bulkhead and welded it in place. The results pleased me and today, for once, the welding went well. Even if the photos make it look worse than it is.

Looking in from inside the wheel arch.

Here's a reminder of how the area looked when I got going with the grinder.

Better, eh? Note new section welded in top right-ish - this supports the new rear bulkead repair. See the plug welds in the last photo.

The rear side of the repair today.

Here I have highlighted the new repair panels to be made. The top one in dark red is now replicated and shown in the photo below.

New metal welded in. It looks better in the flesh than in the photo!