• 5/16” UNF x 11/2” bolts & nyloc nuts (4)
• 5/16” UNF x 2” bolts & nyloc nuts (6)
• 3/8” & 5/16” plain washers as needed
• 5/16” mudguard washers - as needed
• Selection of spacers
• 1/4”UNF x 1” countersunk headed screws & nyloc nuts (2)
• 5/16” UNF x 1” bolts & nyloc nuts (4)
**Note: The door hinges are marked as follows: A - R/H top; B - R/H bottom; C - L/H top; and D - L/H
bottom
Fitting the body to the chassis is very straightforward. It requires 3 people, one lifting each side near the door
positions and one at the front to stabilise and direct.
There are a total of 16 fixing locations for the body to the chassis see Appendix 2, figure 17.
10 horizontal fixings:
• A&F At floor level beneath the scuttle, these take 5/16” or M8 bolts.
• B&E At floor level behind the seats, these take 5/16” or M8 bolts.
• C&D Above the rear suspension behind the seat, these take 7/16” or M10 bolts.
• G,H,J&K The 4 bonnet catch hooks which fasten the inner rim of the front wings to the chassis.
Plus 6 vertical fixings marked with a * in figure 17.
• 2 in the luggage locker area where vertical brackets on the chassis upper member are fastened to the
inner wings taking 5/16” or M8 bolts.
• 4 in the lower flanges of the body frame beneath and in front of the passenger compartment. These
take 5/16” or M8 bolts and fix to brackets on the chassis member.
7.1.1 Lifting on the body
Make sure your chassis is ready to accept your body, if fitted remove your alternator, dipstick and air filters
including the back plates. Fitting the body to the chassis is very straightforward, it requires 3 people, one
lifting each side near the door positions and one at the front to stabilise and direct. Lift the body, walk it to
the chassis and lower it on to the chassis allowing the fixing holes A to K to mate. Take care as the bulkhead
will be very close to the camshaft oil feed pipes, this area could be protected with cardboard if preferred.
7.1.2 Bolting on the body
Bolting the body to the chassis can now commence. It is very important that the fixing bolts do
not place strain on the body because this will pull the door apertures out of line and result in poor shut lines.
The body at fixing points B to E and G to K are shimmed as necessary at the factory before delivery so the fit
should be satisfactory, place the shims or washers in the relevant positions as indicated on the diagram
supplied marked with the red dot. Do not fit A, F and vertical fixings at this point.
Note: Not all positions require a shim, and a gap at positions C and D is not unusual as these fixing
points, when fully tightened will open the door aperture to the correct shape for the door.
Once the shims are in position, the bolts and bonnet securing hooks can now be fitted but not tightened until
all fixings are in place.
Note: Although the holes in the body have been drilled to give a clearance fit for the bolts, the holes in
the chassis may be tight due to the powder coating. If this is the case the powder coating may be filed
out to allow fitment. Try not to file more then necessary to avoid exposing the steel, if steel is exposed
ensure the bolts are coated with grease on fitting to avoid rust forming in the bolt holes.
7.1.3 Body Tightening sequence
Once all shims, bolts and bonnet hooks are in position tightening can commence, the best sequence to tighten
points is B & E followed by G & K then H & J and finally C & D.
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