I know it's been discussed on here several times, and thanks to those who've responded previously. I'll be chopping out the passenger bulkhead sometime in the near future, and thought I'd ask those that have done it, what was necessary to clean up the left overs...? I've seen a few variations on a theme; some have cut the seat pedestal right back, to create a'curved' profile, others have cut straight across.... some seem to have left an upstand... I'll be leaving a gusset (madam) at the bottom of the B post, but where the top tubular section mounts, is this just butt welded, or does it fit into a hole, with a plate around it for support? If you've done this yourself, or have a factory job, close up pics would be great...Thanks
The top tube is fitted into the collar bit but does not pierce the pillar itself. Spotweld drill will remove the collar so if you're deft you can leave barely a trace The top of the gusset (a la Westy) is at the top of the inset dent you can see from sliding door side. the long side is folded over towards the front 5-6mm flange. If you leave more than 10mm measured at the bottom end of the tube, your swivel seat may hit it. I left a bit more and then put a plastic cap on it but the swivel knocks the cap off. I'd leave 5mm next time.
I wish I'd chopped another 5mm off... If you look from the other side there is an return along the end of the tub spotwelded to the bulkhead so i don't see how you can cut it completely flush. I cut mine off lower than mr Westy because I didn't look until after I'd done it.
This is where the collar was - I went a bit far on one spotweld. The blob is a manufacturing locator punched in the steel for the collar - I think it you ground it flat you might go right through so i left it. The series of of little pits is were the the last strip of panel pulled off very easily. Bad pic but there is black trim pressed on it the same as the picture above - worth considering the depth of your trimage when you get the ginder out. I didn't, I got lucky.
