Problems with defender bulkhead fitting.

[julianf]

So, here are the 300 brackets -

But these are the puma ones -

Basically the same, but the slots are cut in the other plane.


Here are mine, in all their rusting glory, for reference -

Im guessing that, with the puma ones, you can alter the tilt better, but the forwards and back not as well.

I wonder if they would work better for me.

 

[MoreWellie]

Loads of overlap. The whole bulkhead needs to tilt forwards, toward the front of the vehical, to sort out that top door gap.

I am guessing the photo above this comment shows the top back corner of the passenger door

from the photo it looks like the door is square with the surround so why do you want to tilt the bulkhead/door? Maybe I need a photo from further away

 

[slim_boy_fat]

Maybe @KimB can throw some light on this, she's been down that road fairly recently.

 

[julianf]

I am guessing the photo above this comment shows the top back corner of the passenger door

from the photo it looks like the door is square with the surround so why do you want to tilt the bulkhead/door? Maybe I need a photo from further away

The green bit is the top of the door. The red bit is the roof. The black (and white) bit *behind* the door is the b post.


The gap is fine at the bottom -

Theres an overlap at the top -

I dont have additional photos,

 

[MoreWellie]

having had my head banged on the pictures again I now see what I am looking at

is the top of the door really square with the roof as it looks or is that an optical delusion?

when you took those pictures what sort of gap did you have between the outrigger and the bulkhead?

what did the gap look like at the front of the door? both on the vertical part and at the top of the windscreen

how did the "shoulder" on the door line up with the one on the B pillar?

How does the shoulder on the tub line up with the one on the bulkhead?

 

[bricol]

So, here are the 300 brackets -

But these are the puma ones -

Basically the same, but the slots are cut in the other plane.


Here are mine, in all their rusting glory, for reference -

View attachment 215257


Im guessing that, with the puma ones, you can alter the tilt better, but the forwards and back not as well.

I wonder if they would work better for me.

Use a hole saw/hole cutter, make a dirty great hole in it to allow adjustment all over the place, bolt them up with jig washers, when in right place, weld washers to the bracket.

 

[julianf]

Get the tape measure out Julian

Just been checking.

Im using the mid outriggers as a reference as the chassis has had a new rear quarter at some point, so cant be trusted there either!

Im assuming measurements #36 and #26 are to the centers of the holes in the tops of the mid out riggers, but its not easy to be sure!

Anyway, ive plugged all my known into CAD, and its not perfect, but also not a million miles out.

#8 on the diagram is 3030.7 to 3028.7 but its not 100% clear if its to the face of the outrigger or the tube.

Tube protrudes by 9mm, so im looking at an error between 4.3mm and 13.3mm, depending on if its to the tube or the face. Diagram above looks like it may be to the face, but this isnt really a relevant dimension (other outrigger is given to hole centres, as they are relevant, not to the irrelevant face, so im not sure)


A 4.3mm error is not a lot. Thats a couple more washers on the foot. 13.3 is getting a bit much though. But theres no chance the outrigger was that far out initially, as i can still see where i chopped the old (original) one off.


Plus, again, is this longitudinal error relevant, as it can all be adjusted (to a limited extent) with the spacers? If i went 14mm (and it may only back, then the doors would start conflicting at the bottoms, and im not sure the floor plates would fit any more.


Im beginning to think i just need a bigger hammer...

 

[stuvy]

How far out is the door?

 

[julianf]

Use a hole saw/hole cutter, make a dirty great hole in it to allow adjustment all over the place, bolt them up with jig washers, when in right place, weld washers to the bracket.

That seems like a pretty good idea.