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post #70 of (permalink) Old 11-24-2013, 11:08 PM Thread Starter
Paul L
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Join Date: May 2010
Location: London, UK
Posts: 907
Bulkhead Repairs - "A" Pillar - Driver's Side - Part 3:
After cleaning up the area & marking up two reference points it was time to take a deep breath & cut.

I clamped the external support structure in place, making sure my reference points were the same distance apart as before.

I started by just welding the left "arm" of this box section to the bulkhead along both the top & bottom edges.
Then what remained of the edges of the bulkhead were hammered over the box section.
I then welded one small section of these bulkhead edges to the box section (I'll finish the rest off later).

Sorry this next photo is so blurred, but hopefully it shows where other parts of the bulkhead were welded to the box section.

There was a supporting bracket inside the A pillar & I welded that to the flat plate on the box section.
( I did finish off welding the right hand side of this bracket after the photo was taken. )

At this point, the bulkhead was already more solid than it was before and I still had the panels to weld in.
I started with the main pillar repair section, which required me to crawl inside the bulkhead to weld all the edges.

Next I welded about 2/3rds of the other panel into place.

This is because I need to cut & shape one end of the panel to blend it in with the curves of the bulkhead.
So after making the cuts, then hammering & welding 2 of the tabs into place it looked like this.

When all four tabs were done it looked like this from the inside.

I know a lot of my work has a Frankenstein look about it, but this is now rock solid.
And with the basic shape in place I was happy that I could smother it in filler to hide the "wounds".

But first, there was a final repair panel to fit...

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