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  • Fixing classic Defender bulkhead rot: Sheet metal fabrication & rust prevention
    Started by kavin_RoverKing
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kavin_RoverKing
Oct 02, 2026, 10:11 AM
Hey boys, documenting a key restoration fix on my 300Td - the infamous bulkhead and footwall rust! Rainwater leaking through the windshield hinge seals had turned both driver and passenger floorboards into Swiss cheese over the years. Instead of buying expensive imported replacement footwells from the UK, took the rig to a local tinkerer in Kurunagala who hand-fabricated replacement 16-gauge steel panels. Cut out every bit of rotten metal, seam-welded the new plates, and coated the entire bulkhead with zinc primer followed by rubberized undercoating. If you've got water leaking onto your feet during rainy Colombo commutes, check your bulkhead corners before it gets out of hand!
Sinith001
#1
Oct 13, 2026, 09:15 AM
Spot on thread! Bulkhead rust is the #1 killer of original Sri Lankan Landies. Did you replace the rubber windshield cowl blocks while you had the panels open?
M10_defender
#2
Oct 27, 2026, 02:53 PM
Proper job Kavin! 👏 The Kurunagala tinkerers are absolute wizards with sheet metal; hand-fabricated 16-gauge plates will easily outlast those thin aftermarket panels. Replacing those cowl rubber blocks like Sinith mentioned is key, but also don't forget to spray a bit of cavity wax like Dinitrol inside the bulkhead corner pillars so it doesn't rust from the inside out again. Awesome thread mate! 🍻
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