I’m tackling a DIY repair on my gen 1 Honda Insight and could really use some expert advice. I’m planning to replace the front Bulkhead Car Part, but I’m facing a few challenges and want to make sure I proceed safely and correctly.
Let me give you some background. My Insight has been through a lot. It had previous accident damage on multiple sides, and I’ve already dealt with extensive brake line rust and previous poor repairs. Last year, I had a front-end collision on the driver’s side, right at the headlight. This impact significantly bent the front bulkhead, essentially turning it into a parallelogram. The upper arms are cracked, and the A/C and radiator are now sitting askew. The insurance company declared it totaled, but I bought it back.
I spent a considerable amount of time trying to straighten the damaged bulkhead and repair the cracks. However, after reassembling everything, the front end still looks misaligned. During this process, we uncovered more evidence of shoddy repairs from previous mechanics – areas that should have been TIG welded were simply glued. Despite these issues, the car has been surprisingly reliable. I’ve driven it extensively, including long trips, and it even passed inspection!
My main concern is the visibly crooked front end and the potential for future problems. I’ve managed to acquire a replacement bulkhead car part assembly, which includes the key components I need to swap out.
My question revolves around the replacement process. I know that on some vehicles, these upper arms are detachable, suggesting that a bulkhead car part replacement like this is feasible. The biggest hurdle for me has been finding a qualified aluminum TIG welder. I’ve located one in Rochester, NY, but I’m in Virginia.
This leads to my main question: Could I potentially cut off the damaged bulkhead, temporarily bolt the new bulkhead car part into place (using non-corrosive bolts suitable for aluminum), and then drive the car to New York for welding? Alternatively, would it be safe to drive with just these bolts securing the upper arms, considering the lower section is more securely attached (bolted to what I believe are the cylinders)?
I’m eager to hear from anyone who has experience with bulkhead car part replacement, especially on a Honda Insight or similar vehicles. Any advice on the feasibility and safety of this approach would be greatly appreciated. I’m committed to keeping my Insight on the road and believe this bulkhead car part replacement is a crucial step.
TLDR: Is it possible to temporarily bolt on a new front bulkhead car part after removing the damaged one, in order to drive the car to a welder for permanent welding? Is this a safe approach for a DIY repair?
