4. Once happy with the fit remove the panels and mark at equal intervals where they will be riveted to
the GRP and drill to size for your rivets, lay the panels back in the bonnet drill the GRP and
temporary bolt the panels in through a few holes while you carry on with the other panels in the same
way.
5. Once happy all the panels are fitting correctly remove the alloy panels and clean off any marks
before bonding and riveting in place, bonding them as well as riveting will help keep panels from
vibrating.
6. Next take the bonnet hinge bracket 131 and secure to the chassis front frame before offering up the
bonnet to the chassis and centre body section, use a trolley jack or similar to hold up the front end of
the bonnet and adjust the height to line up the side of the bonnet to the centre body (the bonnet will
need to be trimmed later to achieve even panel gaps). The positions for the four louvered panels and
the front grille can have most of the area cut out if needed as this can help to view and position the
bonnet.
7. With the bonnet in place the centre section will probably need to be lifted in the middle with a jack
and suitable short lengths of wood to get it to the same level as the bonnet. Once happy with the
position of the centre section remove the bonnet ready to fit the centre section alloy panels.
8. Start by marking the centre of the bulkhead panel and the centre of the chassis where the bulkhead
will bolt, this will ensure the bulkhead and the body will be fitted centrally to the chassis. Offer the
bulkhead to the body and mark any areas that will need trimming, the alloy panel will tuck into a
grove around the top of the centre body section and will need flexing to get it into the sides. Make
sure the alloy panel does not push hard into the GRP as this may show through the body at a later
date.
9. When the panel fits in, as with the bonnet section mark at equal spaces where you will be riveting
and drill for your chosen rivet size before returning the panel to the body, drilling the GRP and
temporary securing with a few bolts through the GRP and through the chassis rail. Make sure the
panels are not pushing hard into the GRP as this may show up later after painting. After this continue
by doing the same with the lower bulkhead panels on both sides of the body, these will overlap the
bulkhead and will be riveted to the bulkhead when fitting the strengthening top hat sections later.
10. Once these panels are also temporary bolted in you should be able to remove any props holding up
the centre section before returning the bonnet to the car to assure the bonnet and the centre section
still line up correctly. If you need to now is the time to adjust the bulkhead panels, when you are
happy the bulkhead and lower panels can be bonded and riveted in place and bolted to the chassis,
also the front end of the body can be bolted the chassis lower rails which will give the body a nice
solid feel now.
11. The bonnet can now be returned once more and lined up with the centre section before drilling the
hinge bracket holes into the bonnet alloy panels and bolting through into the strengthening plates. It
may help to use washers as shims between the chassis and the bonnet hinge to improve the fit and
position of the bonnet. Don’t finish the panel gaps until the rear body and door/s are fitted up and
centre section alloys all fitted.
12. Next turn to the rear body section 150. lay the rear body upside down and fit in the main front to rear
alloy panels, the front alloy panel between them can also be fitted (return facing forwards) but only
mount this to the GRP don’t connect this to the side panels yet as its position will need to be set on
the car.
13. With the rear body ready clamp a piece of wood, which is wider than the chassis across under the
rear end of the chassis to support the rear of the rear body section. The rear body section can now be
laid into place.
14. Check for fit to the centre body section, file if necessary to make the mating surfaces flat before
clamping together and when happy with the alignment drill and bolt the rear section to the middle
using two bolts each side on the horizontal surfaces and on single door cars use a series of bolts
around inside the curved body section. Once happy with the fit move onto the door/s.
15. To fit the doors start by fitting the door hinges onto the doors, the bottom hinge should be
approximately 90mm from the bottom door edge and the top 190mm. The front hinge bolts will be in
the door shut and the rear inside the door casing, using a set square mark the hinge positions on the
door to ensure the hinges line up level (the top hinge will overhang the door).
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