Handbrake Pt1

As with many things in life chores get in the way of having fun, and with the usual work bunfight in Barcelona, rehearsing for a gig and breaking my big toe (in two places) I haven't had much time in January.

And now February. I have just had to have a shoulder operation, which means being in a sling for 4 weeks. Then another probable month before I can do any serious work on the car so I'm catching up with blog posts instead.

So having messed up the thread on one of the body attachment points from over zealous application of the handbrake when first testing it, I drilled out the thread, drilled right through the chassis to underside and aquired a longer bolt and nut to go through - so this is akin to the scuttle hoop attachments bolts now instead. Better in my view.

However the challenge still remains of the handbrake lever position.  With the hole now drilled through the body for the cable to pass through, the natural position for the handbrake to take is shown below

This is too far forwards and the top edge of the bracket is too high against the door sill lip. Next photo shows that more.

And the bottom inboard edge of the bracket will possibly interfere with seat at this point too. I removed and tidied 5mm from inboard edge of the bracket to help with that.

Looking at the image below one of the problems is clear - where the bracket has been welded the heat has caused it to move out of true 90 degree angle - probably removed from the jig a bit quickly. 

Having a brief chat with Jon at AK options were he'd replace it or I could give it a tonk with something heavy to bend the angle in first.

I took the latter and with a couple of large hits got it back to 90 degrees.

The XJS mounting bolts also need trimming down as they will interfere with internal trim panel.

With these things done the position is much better so I painted up with por15 rust prevention paint as the hand rack mechanism has a plastic cover over which I will put a leather cover too,

Finally mounting photo to follow... Which I've now taken and put below.

And no the blocks of wood aren't staying... It's not a Morgan you know!

Roll bars and seat belt mountings

So next on the list of things to do was to open out the roll hoop body holes as these were a very tight fit and would be liable to squeak and rattle if there were any touching parts against the body. This was simply done by marking up with a pen and then carefully using the dremel to open out the holes.

Linked to this are the top seat belt mountings which are attached to a bracket under the rear cockpit return incorporating the rear roll hoop mount.

Top right of above photo there is a forward protruding metal lug into which the upper seat belt eye bolt screws into from the underside of the cockpit return.

This hole is not predrilled so it's a measure, drill pilot hole... Mess it up (due to measuring from wrong end!!! Momentary brain fug)

Once the hole is located in the RIGHT place then open out and test as per below.

Passenger side done without muffing up above.

Not fully screwed in above but these are the official eye bolts, 8.8 strength rating. The holes needed opening out a bit more to allow the eyebolt to screw right in.

Now I just need to locate and open out the lower holes either side of seat positions and chase out the threads ensure there's no powder coat blocking them.