Modifying the bulkhead

Click for bigger picture.

The cage tube passes through the space.

Perhaps one of the most awkward bits is modifying the bulkhead to accept the roll cage - the Dakar build manual is very vague about what to do, so I will attempt to explain my method.

Note that this is for guidance only and measurements are approximate. Bulkheads vary with year of manufacture - this is the "early" type.

Update March 2005
This page was mostly created for Steve Knight after he asked me for more detail about the mod'.
I have modified the instructions as the result Steve's refinements: cutting closer to the firewall to get more clearance, and slanting the cut to match the arc of the flap as it is pushed inwards.
You can see how Steve did it here.

First, remove the end of the scuttle box as indicated by the large red area on the main diagram.
The horizontal cut is level with the bottom of the scuttle box.
The rear slanted cut follows the slope of the back of the scuttle box.
The front slanted cut takes a line from the top of the front edge (with the holes for the spire nuts), through the drain-hole and finishes just behind the firewall seam (which is clearly visible in the bottom of the scuttle box).

Also remove the small red section from the end plate (about 25mm x 15 mm) to provide clearance for the flat fixing bracket on the cage.

Referring to the inset diagram which shows a plan view of the left hand end, remove the red area between the A-post and about 10mm behind the firewall seam (see pic under diagram).
Now make 2 cuts indicated by the red lines on the main diagram. The vertical is cut down to the bottom edge of the reinforcing strip on the inside of the footwell (see other pics). The horizontal cut follows the line of this strip back to the edge of the A-post.

The 150mm square "flap" produced by these cuts is now pushed inwards and welded to the bottom of the scuttle box which had the triangular section removed earlier. At the lower front corner, it only needs to be pushed in by about 25mm.

Cut a long, thin right-angled triangle (about 50 x 300mm) from steel sheet and fold a right-angle in the middle. Weld this piece into the gap at the front and bottom of the "flap".

Repeat for the other side, and it's done.


From inside the footwell....

.... you can see the lines that the cuts follow.