Category:Build Manual

From GTM Workshop

Contents 1 Build Manual 2 General Build Principles 3 Use of the manual 4 Working Glassfibre 5 Safety 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

General Build Principles

Wherever possible try to complete an assembly before moving on to the next assembly. Assume when fitting the components to the monocoque that this is it and for good and not to be repeated later. Experience as shown that any assembly task not done properly will eventually lead to problems in service. For example when fitting the heater blower unit try to fit the heater in the dashboard and the air pipe at the same time so that the whole assembly is complete. Do not assume that you will be taking the heater blower unit off again, and therefore make sure that the seal is working correctly and water will not run into the car at this stage.

Use of the manual

In order to eliminate constant duplication the text of the manual refers only to the Libra, however the Spyder assembled can be assumed to be the same. A supplement can be found at the rear of this manual which covers the areas of assembly unique to the Spyder. The manual in no way attempts to describe the mechanical assembly of the components used on the GTM Libra but purely how these components fit in the GTM Libra. The assembler may well find the use of the appropriate Haynes manual to be helpful in this regard. The build sequence helps the assembler to assemble the car in the most efficient manner. The actually assembly of these components and their detailed description of assembly are contained in the paragraphs in alphabet order. If during the build or your Libra you have difficulty understanding the manual or it is not clear please con-tact the factory who will be pleased to help and of course enable the manual to be improved for subse-quent customers.

Working Glassfibre

Glassfibre can be worked using normal metalworking tools but however blunts these tools very quickly. When drilling holes it is strongly recommended that before putting the correct size drill through a small pilot drill is used to pick up the centre of the hole marked on the component. Glassfibre can be cut with a sharp wood chisel and sanded with production paper. A face mask should always be worn when cutting glassfibre. It is strongly recommended that after any cutting or drilling you immediately vacuum up the dust. Should your skin be particular sensitive to glassfibre dust the wearing of lightweight disposable latex gloves is recommend.

Safety

A motor car can be a very dangerous. Particularly when assembling brakes and steering components. Be absolutely sure that they are assembled correctly. If you have any doubts please contact the factory, who will be only to pleased to clarify the correct assembly procedure .It is the assemblers responsibility to build a Safe car. Once you have completed the assembly of your Libra and before taking the car for its first drive check once again the braking and steering components.