3. Next offer the door/s to the body and pass the hinge studs through the body. On the inside of the
hinge studs fit on star washers (these help the hinges grip to the body) followed by the plain washers
and Nyloc nuts. Adjust the front and lower door to body gap before tightening the four nuts on each
hinge. With the doors secured to the body centre section and the gaps correctly adjusted, lower and
raise the rear of the rear body section to set the door gaps at the rear of the door/s making sure that
the doors open and close without rubbing on the rear body. The bolts in the centre can also be
released if necessary to allow a small amount of sideways movement to help align the door/s to the
body.
4. Once you are happy with the position of the rear body and the door/s, the rear body can be secured to
the centre body alloy panels at the rear of the door’s apertures with either pot rivets or slot headed
screws and nuts in good equal spacing as these will be visible when finished. The rear body alloy
inner panels also need securing to the rear frame along the lower angle section, the diagonal angle
section and the vertical angle section under the fuel tank with equally spaced pot rivets. These lower
and vertical angles also seal the boot so need a rubber or foam strip or a bead of silicone laid on
before securing. The rear support can now be removed. Next the fuel tank neck can be centralised in
the rear body aperture and the fuel tank straps tightened down fully. Once you are happy with the fit
of the rear body and door/s the door latch and catch (147) may be fitted. Adjust and shim where
necessary to allow the door to sit level with the body before fitted the door rubber and/or foam seal
(148).
16 Rear valance and spare wheel cover
Parts required 151,154
1. Before fitting the valance (151) bond a rubber strip along the top horizontal face of the rear valance.
This will seal the valance to the rear body and give the boot lid a rubber seal to sit on. The rear
valance can now be secured to the rear body with the four M4 bolts supplied and can be riveted
through the belly pan into the rear frame. Finish the rear valance by trimming and locating the rear
valance end caps (may already be fitted to valance) and rivet in place. Seal any small gaps with
sealing tape or silicone sealer.
2. Next take the spare wheel cover (154) and find the turn fasteners, these 2 winged fasteners come
with 2 plastic washers each. Fit one washer on each before passing through the boot lid and fitting
on the second washer. The first washer protects the boot lid from the fastener rubbing and the inner
washer stops the fasteners from falling out when the boot lid is removed. Trial fit the boot lid to
ensure the two lower pins and the top fasteners line up with the positions in the body and adjust the
position of the rear valance or file holes a little if necessary. When you are happy with the fixing
positions fit the two spring catches on the inside of the rear body lip, these will need small washers
fitted as spacers to adjust the position of the spring for fitment of the boot lid. If the boot lid is too
loose fit extra washers to pull in the boot lid until it lines up with the rear body. Now remove the
boot lid and stick on the foam seal on the inside edge of the boot lid, but not along the lower edge as
this is sealed by the rubber strip along the valance.
17 Rear lamps
Parts required 099-102
1. To aid positioning of the rear wiring harness start of by fitting the number plate lamp (102) (this will
centralise and locate the wiring harness). The base of the lamp should be approx 25mm above the top
of the boot lid. Use the rubber base as a template to position the holes to be drilled for mounting and
wiring. The number plate lamp can now be mounted and wired. Use one of the mounting bolts to
secure the wiring inside the boot with a P clip. If you are having roundels and want to fit a rear lamp
for these then you will need an extra lamp the same as the number plate lamp. This can be wired in
with the number plate lamp but will need a hidden switch in the boot, as the lamp cannot be used for
driving on the road.
2. The wiring harness can now be taped to the underside of the rear body towards the rear lamps. Drill
and grommet holes in the rear side panels to get the wires from the boot to the stop/tail lamps (099).
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