Monday, 13 April 2020

Aerocatches and Carbon Fibre Flared Side Panels and Headlights

Due to COVID-19 the cars are both in extended lockdown, me working from home and the Easter holiday trip to Berlin cancelled I've managed to get out to the garage and complete some upgrades to the SEIW.


First was the headlights, the shells needed to be finished off with fittings

and once the LED headlight had been bonded in place I fitted them to the car using new 6 way econoseals and the same wiring as the previous lights

Aerocatches - (note photos from either side)

Next was the Aerocatches, I'd had these and the flared side panels for a couple of years but never plucked up the courage to fitment - I now know why.

Step 1 - decide where to fit them and make a template so that both sides are in the same position.

Step 2 - cut out the mounting hole

Step 3 - sand down the thickness of the panel/trim the Aerocatch

Step 4 - bond in the aerocatch

Step 5 - cut slot and shape the lower edge of th e bonnet to clear the pin

Step 6 - make a bracket and mount the engagement pin (note after fitting the flared side panel

Step 7 - repeat on other  side

Flared Side Panels (removable)

Step 1 - drill out the current side panel rivets and cut the panel just in front of the footwell bulkhead - I took the opportunity to clean off some slight rust and repaint the chassis 

Step 2 - cut the top edge of the new panel to length/shape (including ARB cut-out) and drill the upper mounting holes using a 'hole finder' and 'clecos'

Step 3 - drill the mounting holes out to 7mm, countersink and fit M5 rivnuts

no photo

Step 4 - drill the lower mounting holes using a 'hole finder'

no photo

Step 5 - mark and cut the side edge of the flared panel following the angle of the scuttle

Step 6 - make a template for the grill - using the profile of the old/new panel at the new cut angle

Step 7 - mark out, cut and form the grill, then touch up

Step 8 - bond the grill to the flared panel witk sikaflex - use self adhesive foam to protect the inner panel (following the masking tape)

Step 9 - repeat with n/s needing the exhaust & exhaust manifold removed and extra cut out.

Now just need to get the car out of the garage for a good clean and polish.

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