Radiator ducting and splash moulds to monocoque

From GTM Workshop

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

The front end of the Libra is held together by the radiator ducting mould. It is bolted to the monocoque. The design is such to allow a degree of crash protection in front of the monocoque the radiator moulding, battery moulding, bonnet hinges etc. all mount to the radiator ducting mould.

Assembly

The radiator ducting TO107 attaches to the monocoque TO100 using six 6 millimetre set bolts 25 millimetres long nylon nuts and large diameter washers With the ducting resting on the car, on the two vertical faces that come up against the monocoque can be seen two indents where the 6 millimetre bolts fit. Remove the moulding and drill these two holes with a six-millimetre clearance hole.

Replace the radiator ducting and position snugly on the monocoque and mark the two holes. Remove the ducting and drill these two marked holes a good 6- millimetre clearance i.e. 8 millimetres. Make sure that the top face of the radiator ducting moulding protrudes above the top surface of the central monocoque by approximately 15mm to enable the rubber trim moulding to fit correctly. Replace the ducting and bolt up the ducting to the monocoque using two of the 6 millimetre bolts.

Now looking from the top of the radiator ducting and inside the ducting adjacent to the heater blower unit and the pedal box two further indentations can be seen for the mounting bolts. Holding the ducting snugly against the monocoque drill these holed 6-millimetre clearance.

Remove the ducting and open out these holes to a good 6-millimetre clearance i.e.: 8 millimetre Replace the ducting and secure with 6 millimetre bolts, nylocs and washers. When bolted up there is a deliberate slot on the rear edge between the moulding and the monocoque to allow water to drain. Do not fill this slot with silicone sealer.

Now working from within the wheel arches drill a 6-millimetre clearance hole through the ducting and the monocoque on the flange of the ducting approximately 15 millimetres from the first angle of the wheel arch on the monocoque. Bolt through with 6 millimetre bolts, washers and nyloc nuts.

Two small splash moulding TO112/3 are attached to the monocoque using number 8 self tapping screws and washers to finish off the seal path of the wheel arches. The shiny side of the splash mouldings face towards the door closures. The splash mouldings have a rebated portion that fits over the end of the radiator ducting.

The shape of the splash moulding positions itself and working from the inside of the wheel arch attach the splash moulding to the monocoque. The top edge of the splash mouldings want to align with the top edge of the radiator ducting. At the top end of the splash moulding where it goes over the radiator ducting drill through both splash moulding and radiator ducting to allow both components to be attached using the self-tapping screws. When attaching with the self-tapping screws drill a clearance hole in the splash mouldings arid the radiator ducting and the appropriate tapping size holes in the monocoque.