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 Post Posted: Mon Nov 04, 2013 9:45 am 
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Joined: Tue Nov 27, 2012 11:59 am
Posts: 384
Location: Sunshine Coast, Qld
Good Morning and welcome to a bit of real work and slight frustration at times.

Before fitting the bonnet and dash the sidepods need to be fitted.

Depending on when and how (trimmed and primed or straight out of the mould) you bought your panels the amount of trimming required will vary.

The inside bottom edge of the pod should be sanded flat so there is no lip at all, the top inside edge should be kept intact but neat and smooth. The amount of 'return' is much reduced towards the rear of the panel. The area around the dash cross tube needs to be finely trimmed to suit your chassis no matter how we have trimmed in store as that's one area we leave up to you. The leading and trailing edges are just trimmed and sanded straight or to suit your taste. The trailing edge should still have about a 5-6 mm return on it, the front, none.

Firbreglass is a cow to work with...... Use long sleeves and possibly gloves and in theory a dust mask. Apply large quantities of common sense. A dremel is handy for fine stuff as is course sandpaper and a grinder with either a 1mm cutting disc fitted or a diamond blade of some sort is perfect for longer cuts.

BTW, the sidepod fits over the top bar first and then slides in at the bottom, hence requirement for no lip. It will still be tight fit and a small length of timber or similar will be required to push the bottom lip down from inside to enable it to slide over the chassis. Careful relieving of thickness of top lip to enable fitment maybe required.

Pics attached - more coming soon.

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 Post Posted: Tue Nov 05, 2013 2:09 pm 
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Location: Sunshine Coast, Qld
More pics

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 Post Posted: Mon Sep 01, 2014 8:59 am 
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Joined: Sun Apr 20, 2014 5:38 pm
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Hi Andrew, As there is 4 ways this Bonnet bracket can be installed could you please tell me if this is correct, If not please show me the way.


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 Post Posted: Tue Sep 02, 2014 5:50 am 
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Joined: Tue Nov 27, 2012 11:59 am
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Location: Sunshine Coast, Qld
Perfect! And yes tabs fold up. Marks you have made look about right. 3 layers of chop strand (450gsm) all around the bracket obviously leaving the outside of it alone so as hinge 'tongues' can pivot as per your rough assembly photo. I have found if you measure from the lower most aft edge of the bonnet (from each side) and position the bracket (hedgehog folded bracket) symmetrically in that bottom lip of the bonnet that positions the bonnet appropriately for good alignment with the sidepods and dash. It is also a reasonable idea while you have the resin and mat out to strengthen/brace the area of the bonnet where it meets the dash and you of course also need to mount the bonnet catch once you have the bonnet fitted to the car and therefore know where to glass it in. If glassing around the area where the dash fits into the bonnet I recommend fitting the dash into that area and taping it in place so the radius of the curve on the bonnet over the dash remains fixed.

Andrew.

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 Post Posted: Sat Sep 06, 2014 7:05 pm 
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Ok I decided to flip the Bonnet hinge upside down as it allows me to fully glass both sides when finished. It is sitting very nicely and there is no touching of body or anything. Cheers


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 Post Posted: Thu Dec 24, 2015 10:27 pm 
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Joined: Tue Aug 11, 2015 9:36 am
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Location: Mannum, SA
Hi Andrew, any hints on fitting the seats. It is a very tight squeeze, maybe a trick or two?

Terry :roll:


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 Post Posted: Tue Jan 05, 2016 11:10 am 
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Location: Sunshine Coast, Qld
Further details coming on seat fitment but it more or less drops in from the passenger side first. A couple of slots need to be cut out to allow the chassis tubes to fit. As I say - pics coming.

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 Post Posted: Tue Jan 05, 2016 1:22 pm 
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Location: Sunshine Coast, Qld
Pics of the seat trims/cuts required. Please note this particular seat panel could do with a final trim sand along its edges. Its the rough one we keep in store for check fits.

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 Post Posted: Sat Jan 09, 2016 11:12 am 
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Location: Sunshine Coast, Qld
The Gen2 chassis has quite a few additions to the original design and one area we worked on making easier to assemble was the fitment of the dash.

The outer brackets are now included with a kit and facility has been made for a central bracket to adjust the rake of the dash to suit the fitment to the trailing edge of the bonnet.

We don't supply the central bracket/brace but a length of small section flatbar with a hole at one end and two at the other (the end that bolts to the underside of the upper lip of the dash) with a 90 degree twist in the middle will suffice. Any other arrangement that you think might work will do to of course.

The dash once appropriately trimmed should match the shape of the bonnet aft edge curve and fit within it nicely. In other words, once fitted the bonnet should close nicely against the upper edge of the dash. Fitting the bonnet first and adjusting it so it fits symmetrically is a good start for dash fitment. Its all a bit of a kludge to some degree though and some interpretation and personalisation is possible. Its not a bad idea to have the sidepods fitted as well as they are very slightly asymmetrical in that bonnet edge, dash end, front of sidepod area.

The out brackets need a small bend (up towards the lower lip of the dash)(screw them down to the inside edge of the dash as pictured) in them for perfect fit. A vice (with soft faces) or a press (as pictured) will work quite well. No fancy equipment required.

Positioning is fairly common sense.

Feel free to ask questions here if you have any.

Thanks, Andrew.

PS.

I use M5 screws, M4 is probably fine too.

The slotted hole on the left hand edge of the steering column bracket is the lower single hole mounting point for the central dash bracket/brace. The slotted hole of course giving some easy adjustability of dash rake.

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 Post Posted: Sat Jan 09, 2016 11:31 am 
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Location: Sunshine Coast, Qld
There is further details here - viewtopic.php?f=5&t=43

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