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Advice on rust on Defender td5 bulkhead

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Just got MTs

Joined: 22 Feb 2009
Odometer: 275
Location: Hampshire - the county of green lanes

PostPosted: Fri Apr 24, 2020 8:49 pm    Post subject: Advice on rust on Defender td5 bulkhead Reply with quote

I have taken there fascia off, to inspect for rust. It does not look too bad at first appearance, but I know the bulkhead rusts from within and I need some advice on where to look and what to do to stop it, as I'm worried I'm missing things.

There is a bit of rust in both foot wells; my plan is to remove the base plates (and replace the rusty screws, Land Rover appears to have used un-galvanised ones!), treat with Kurust followed by underbody seal underneath and paint inside. Will that do the job?

There is also rust underneath the windows near the door hinges, which worries me more. I can't see any rust in the engine compartment so I assume it's rusting from within. My plan is to drill some holes in the rust areas, treat with Kurust and inject liberal amounts of Waxoyl, and also into any other hole I can find ((such as the screw holes for the door hinges). Will that work?

Finally - where else do I need to look? I see no signs of rust anywhere else inside the car; from within the engine compartment it's hard to determine although I don't see anything.

And I don't seem to be able to get the pictures the right way round...

Passenger footwell ( upside down)

Driver's foot well (upside down)

Passenger's side bulkhead (upside down)

Driver's side bulkhead (turn 90 degrees cw)

Manage the unavoidable.
Avoid the unmanagable.
(stolen from a traffic sign in Bangalore, India)

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