Build sequence - GTM Libra

From GTM Workshop

Contents 1 Build Manual 2 Monocoque 3 Build sequence - Front end 4 Rear end 5 Doors 6 Finishing Build Manual Build Sequence Monocoque Front End Rear End Doors Finishing Donor Components Rover Metro Donor Components Rover 220/420 Components Build Sections Battery Beam end covers Bonnet and front spliter mould Boot bootlock and hinges Brake lines Carpets Dashboard cover Doors Engine cover moulding Engine frame Engine and auxiliaries Exhaust Front suspension Gear change Handbrake lever cables and calipers Door panels Trim Headlight covers Heater and pipework Lights Part trim panels option Pedal box and master cylinder Perspex screens rear and side Petrol tank filler neck and cap Pipes and services through the tunnel Radiator ducting and splash moulds to monocoque Radiator mould radiator and pipework Rear suspension Roof panel Seat belts Seats and runners Separate instrument option Setting up the car for the road Soft trimming Spare wheel mould and spare wheel Steering rack and column Throttle pedal Trimming hard panels Windscreen and rear bulkhead screen Windscreen washer bottle pipes and jets Wiper motor and blades Wiring Wiring loom insruments and fuse box 1800 gear change p.g.1 gearbox 1800 engine mountings 5AS alarm units Hydraulic clutch 1800 engine steady Spyder Supplement Top Seatbelt Mounting Hood Boot Engine Compartment Grills Stainless Steel Mesh

Listed below is the suggested build sequence for the major assemblies on the GTM Libra. The sequence as been devised to eliminate unnecessary work caused by the necessity to remove already assembled components to fit others.

It as been assumed that the assembler does not have an engine crane but is reliant on manual effort.

The Libra can be conveniently seen as five component parts. Main monologue, front end, rear end, and two doors. To give maximum space in a limited area it is best to store mouldings not being assembled else where. It is best if these components are stored in a dry area and only covered with a cloth type material.

It is extremely important that the glassfibre components are not stored with a PVC type cover over them as this can lead to deterioration of the finish of the glassfibre mouldings. On no account must the mouldings be left outside covered with a car cover as this could lead to severe deterioration of the surface finish.

The monocoque should be positioned in the centre of the assembly area at a suitable height to enable access to the under body areas and in particular the tunnel Two standard wooden trestles would be ideal. With the monologue so positioned it is possible to assembly the vast majority of the car without moving it. The engine and gearbox will not be fitted at this height but will be fitted at the end of the build once the monologue as been lowered to the normal car ride height. Note as the car is assembled it will gain in weight considerably and therefore it is extremely important that the trestles that support the monologue is sufficiently strong to carry the partly assembled car. Do not assume that if the trestles will support the monologue they will support the assembled car.

Monocoque

1. Cut hole for the heater blower.
2. Build up front suspension- complete.
3. Build up the rear suspension (minus hubs).
4. Fit steering rack.
5. Fit metal brake pipes and brackets.
6. The fit hand brake lever to the tunnel and cables above the petrol tank.
7. Fit gear change bracket to tunnel and cut hole for gear change lever.
8. Fit aluminium heater pipes to the tunnel and rubber pipes over petrol tank.
9. Fit speeds cable into tunnel and above all petrol tank.
10. Fit radiator vent pipe tunnel and above petrol tank.
11. Fit the vacuum pipe in tunnel and above petrol tank.
12. fit battery deeds in a tunnel and above a petrol tank.
13. Fit wiring loom to tunnel and above petrol tank.
14. Fit a petrol tank to monocoque, including filler cap and pipe work.
15. The fit radiator pipes to tunnel.
16. Fit clutch cable to tunnel.
17. Loosely fit beam end covers.
18. Fit seat belts.

Build sequence - Front end

1. Fit radiated ducting to Monocoque.
2. Loosely fit battery holder to Monocoque radiator ducting.
3. Fit radiator moulding to deducting.
4. Fit radiator and fan to mould.
5. Fit radiator piping to tunnel aluminium pipes.
6. Fit to wiring loom in ducting through to dashboard top.
7. Fit heater mixer unit under the dashboard.
8. Fit the heater water pipes from unit to aluminium pipes in the tunnel.
9. Fit washer bottle jets and pipe work.
10. Fit battery moulding.
11. The fit battery and battery Leeds.
12. Fit spare wheel Holder and spare wheel.

Rear end

1. Lower car to the floor with front wheels fitted.
2. Fit engine and gearbox to engine frame.
3. Fit rear hubs and drive shafts.
4. Fit exhaust system.
5. Pipe up cooling pipes.
6. Pipe up heater pipes.
7. Fit header tank bottle and pipe work.
8. connect battery Leads.
9. Fit and connect the rear wiring loom and mount ancillaries.
10. Connect petrol pipes and mount filter.
11. Fit gear change.
12. fit throttle cable.
13. Fit hand brake and cables.
14. Fit flexible brake pipes.

Doors

1. Fit outer handles and opening buttons to door shells.
2. Fit key locks to door shells.
3. Fit latch to door shells.
4. Fit lock and latch rods.
5. Fit nylon top hat bushes to door shells.
6. Fit Metro channels to bottom of door glass.
7. Fit rubber channels into door inner frames for glass.
8. Fit glass and regulators to inner frames
9. Fit inner frames to door.
10. Fit doors to a monocoque.
11. Fit door mirrors 12. Fit inner doors to doors.

Finishing

1. Fit instrument to dashboard.
2. Fit fuse box to dashboard.
3. Fit dashboard wiring loom.
4. Connect GTM loom to Metro loom.
5. Fit pedal box and pedals.
6. Fit heater blower unit and air joiner.
7. Fit fresh air vents to the dashboard.
8. Fit fresh air plenum chamber.
9. Fit top dash and demister vents to heater.
10. Fit trim to car.
11. Fit bonnet.
12. Fit front lights and wiring.
13. Fit air splitter.
14. Fit rear panel.
15. Fit rear lights and wiring.
16. Fit Boot complete.
17. Fit screens.
18. Prepare the car for the road.