Firewall

Most of the body work on a Land Rover is corrosion resistant aluminum; however the firewall is made from steel as such vulnerable to rusting. The firewall forms a barrier between the engine compartment and the passenger compartment as well as the mounting point for dashboard, pedals, windshield and brake booster. While not as visible as hinges or a frame cross member, the Firewall is a common area for corrosion.

Corrosion in the toe boxes of defenders is very common. It is possible to make a good repair that will often outlast the rest of the firewall. Unfortunately if the floor boards are rusty, rust has probably started internally in the door posts and the upper corners where the windscreen mounts.

The different layers of steel that make up the floor might be good for the initial manufacturing process and cost savings, but trap moisture and dirt that accelerates corrosion.

Here you can see the repair panel we made. It is fabricated from 16 gauge galvanized steel in one single layer. Once welded in it is seam sealed. Seam sealing is absolutely critical to keeping the moisture out of a weld or seam.

After seam sealing the panel is repainted and undercoated.

We also use Waxoyle on the internal cavities like the door posts. This will help slow down any rust that is starting to occur internally.