Discovery 1 Bulkhead Repair Package with Fitting

Bulkhead Repair Package with Fitting for the Discovery 1: galvanised footwells, top rail and door pillar sections welded in without a body off job.

A Defender or Discovery 1 is only as good as its chassis, and the original was painted steel that rusts from the inside out: rear crossmember first, then the outriggers, then the main rails behind the rear wheels. A galvanised replacement chassis is the permanent answer and adds decades to the vehicle. The bulkhead rusts in the footwells and along the top rail, and on a Defender it is the other half of the same decision. The Discovery 1 shares its chassis design and drivetrain with the Defender and the Range Rover Classic, and it rusts in the same places.

Specification and fitment

• Fits: Discovery 1, chassis code LJ
• Engine: 200Tdi and 300Tdi diesel, 3.5 and 3.9 V8
• Production dates: 1989 to 1998
• Quality: Galvanised or Painted
• Part number: cross referenced to the factory part number for your VIN and confirmed before dispatch, because supersessions on these vehicles are frequent and one printed number would be wrong for somebody
• The failure this addresses: bulkhead rot in the footwells and pillars
• Labour time: about 24 hours, included
• Coding: none. This vehicle predates the modules that need it
• Also needed: seam sealer
• Torque: welded
• Weight: about 40 kg
• Warranty: lifetime against rust through on the galvanising, two years on the parts

What arrives

• Footwells
• Top rail
• Pillars
• Welding

Fitting

Labour guide: about 24 hours, included. Land Rover changes specification mid production, often by VIN rather than by model year, so send the VIN or the registration with the order and we confirm the part against the build data before anything leaves. It takes two minutes and it is the difference between a part that fits and a return. We are an independent Land Rover specialist and parts supplier. We are not Land Rover or Jaguar Land Rover and are not appointed by them; the model names are their trademarks and are used here to describe fitment. Everything we sell is chosen for vehicles that actually get used: towed with, loaded, driven through water and parked in fields, rather than for the brochure.

Which version to buy

Galvanised is hot dip galvanised after fabrication, inside and out, which is what stops the rust that finished the original. Painted is supplied in black primer and top coat for a correct appearance, with cavity wax recommended after fitting.