Tag Archives: front shroud

Front Shroud Badge Replacement

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They just don’t make them like they used to! The shroud badge I mounted on the Healey around 2008 started to lose its color (enamel?) this year. I think the problem was that the entire badge was chromed and then the enamel was applied. It is hard for anything to stick to chrome indefinitely. So, my 2008 badge wasn’t as good as the original.

Shroud Badge Losing Enamel

But…the badges available now are not as nice as the ones that were available when I did the restoration. I had to return one vendor’s badge that wasn’t very good at all. I then ordered one from AH Spares, part # BAD-107, and while the metal is thinner than the one it is replacing, it does have the curvature of the shroud and the lettering and enamel look pretty good. We will see how long the enamel holds up on this badge! The badge has two studs and came with the fixing washers and nuts – a 5/16″ wrench is used.

Replacement Shroud Badge

Chapter 84 Week Fifty-Four December 24, 2007

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Today (Monday) is Christmas Eve and there is much to be done, so only a little Healey work will happen on this day, but I had a good week. I did manage to install the rubber buffers on the front shroud sill bonnet opening. Three on the left side and two in the right plus the long strip to protect the carbs from the weather. My long strip is cut into two pieces to account for the carb access panel. The buffers are held in place by copper-colored split rivets and flat washersthat are pushed through the mounting hole and then bent over.

LH Rubber Buffers

RH Rubber Buffers 2

LH Carb Panel Seal

The next task was to fit the front wings to the superstructure. I began with the RH wing, thinking it would be the more difficult of the two. First, I tapped the wing clip nuts onto the wings. Three shorter nuts and bolts are used for the front of the wing, below the headlights. With the help of my wife, who held the wing in place, I installed the rearmost and forward most bolts.

With those two holding the wing in position, I then began to install the other bolts working from the front to the rear. Each one was hand tightened enough to get them started, but with enough room to install the wing beading. The fourth nut/bolt from the front requires Houdini to install. I finally accomplished it after loosening each of the four bolts securing the heater blower and then disconnecting the large fresh air hose from the blower. With the hose loose I was able to access the bolt for the fourth hole.

RH Front Wing 1

RH Side with front wing

To protect the paint while installing the beading, I ran a strip of painter’s masking tape on the shroud and the wing parallel to the beading.

Beading Installation

After carefully spreading the beading folding tabs so that they were evenly distributed across the wing, I pressed it in place. Once again, four hands come in handy!

With my wife applying downward pressure on the beading I tightened each bolt/nut until the beading was locked in place and the top of the wing was tight.

Then I tackled the three fasteners below the headlight. These are much easier to access. Again, I loosely attached each of the three and then inserted the two plastic beading pieces between the panels and tightened down.

Next were the three 1/4” x 3/4” long hex head bolts used to secure the bottom edge of the wing. Finally, the 3/8” sheet metal screws were used to fasten the wing flanges to the hinge pillar plate. The heater blower fresh air hose was reinstalled and the blower’s four mounting bolts tightened. A little red touch-up paint on the lower bolts and pillar screw heads and then it was on to the LH wing. NEXT TIME I WOULD WAIT TO FASTEN THE WING AT THE BOTTOM UNITL THE DOOR IS INSTALLED. THERE IS FLEX IN THE WING AND BY MOVING IT UP OR DOWN SLIGHTLY ONE CAN BETTER MATCH UP THE WING CURVATURE WITH THAT OF THE DOOR!

The LH wing was a little easier to install in my case because of the carb access panelI had cut into the shroud! The difficult nuts/bolts on the LH wing were the rearmost two because the wiper motor restricts access to the locating holes and hardware.

It was a good feeling to have all four of the body’s wings in place.

The next task was the installation of the scuttle seals that I had ordered from Bill Bolton. These are reputed to the best available, and the fit does seem to be quite nice. As I was working on the seals and dash pad I had a visit from grandson #2, Shane. As the image shows, he seemed right at home in the Bloody Beast.

Little Shane’s visit to the Garage

Little Shane’s Visit

Fitting the scuttle seals was not as difficult as I expected. The job was made much easier by following directions: Scuttle Seal Install Rich Chrysler along with those provided by Bill Bolton.

Scuttle seal 1

Scuttle seal rivets 1

scuttle seal screw holes

Scuttle seal rivets 2

I then installed the dash pad, along with the hot air outlet defroster masks, the mirror, tonneau turnbuckles, and the stud for the tonneau cover.

Dash Pad seal 1

Dash Pad seal 2

Once the dash and accompanying hardware was installed I was ready to begin the door installation. I first attached the door check strap assembly to each side. Then I taped all the edges of the wings, sills and doors with painter’s masking tape for protection.

Check Strap Assembly 2

Check Strap Assembly 3

My son John (23 years of age and strong) lifted the doors in place and I ran in the door hinge screws. This job was actually easier and less time intensive than I imagined. Of course, I still need to adjust them for proper fit. I had previously attached all the door interior upholstery, trim and hardware which was much easier than installing it all on the car, but it did make the doors quite heavy.

Next on my list was the installation of the headlight buckets, headlight bulbs, and the chrome lens retaining rim. It wasn’t necessary, but I jacked up the front of the car and temporarily removed the splash shields and the tires to give easier access to the rear of the headlight buckets. I experienced a little difficulty with mounting the trim rim but eventually got it to lock into place. Then I secured the parking/flasher light assemblies to the car with the three small machine screws and nuts, and put the clear lens in place.

Headlight installed 1

Headlight installed with lower wing beading

I thought I would check out the fit of the grill and immediately noticed that the horns were preventing the grill from sliding into place. I did not have the original horns and I am using later replacements (these are deeper). I ended up switching the LH and RH units and placing them inside their mounting bracket and this seemed to give me the space I needed for the grill. At some point I would love to find the proper horns!

Horn installed

Now it was on to the tow hook/driving light bracket from Cape International. I bolted the brackets into place and fit the Lucas 570 SLR- 5” driving lights, attached the wiring and tested the lights to find them working beautifully. I had previously installed the light relay, an indicator light and the wiring so that the lights only come on when the bright beams are used.

Auxiliary Driving light bracket and tow hook

My final work for the week was the installation of the three pieces that comprise the front grille. These were fixed to the car without any issue. The splash panel brackets on either side of the car were fastened to the outside grille mounting brackets.

Grille and Lights installed

Side View with both wings and door

Chapter 83 Week Fifty-Three December 17, 2007

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This week begins my second year of restoration assembly. I have some time off in the next two weeks so I am hopeful that at the end of the Christmas holiday I will have my front body components on the car.

While waiting for the carb repair, I decided to start a little work on the hardtop assembly. Most of my hardtop restoration components came from Bill Bolton. The hardtop fabric he supplies is very close to the original. I has previously refurbished the headliner frame and had it along with the front cushion covered by Gerry Smith at Classic Upholstery. I glued the fabric to the lower hardtop aluminum cant rail.

hardtop fabric on rail 2

hardtop fabric on rail 3

Fabric was also glued into the corners of the hardtop where the front mounting “J” hooks are located.

hardtop corner fabric

Then I glued some carpet padding onto the hardtop to provide cushion for the headliner frame rails.

hardtop carpet cushion for headliner rails

My repaired front carb returned from Joe Curto yesterday (December 18). Joe replaced the diaphragm. I installed the carbs last night and pleasantly, no leaks! Now I will leave the hardtop work and return to installing the body.

Front SU carb re-installed

I covered all of the edges of the scuttle that come in contact with the front shroud(bonnet surround) with 3M strip caulk. This will prevent heat, fumes and water from entering the cockpit. To make sure I had adequate build up of the caulk, I used a tip from Jack Brashear. I covered the strip caulk on the scuttle with wax paper, installed the shroud and then pulled it off. Where the strip caulk was not pressed against the the wax paper I added more caulk and repeated the process until I was satisfied that I had enough caulk in place.

Shroud strip caulk 2

Shroud strip caulk 1

Ready for the shroud 2

Securing the front shroud to the superstructure was the next step. I began by installing 3/16” aluminum pop rivets in the rear of the shroud along the dashboard flange (5) and scuttle edges(2 per side).

Shroud rivets

I then installed five countersunk flat head screws through the rear flange of the bonnet opening into the edge of the firewall.

Four bolts, washers, and nuts fasten the frame rails to the shroud at the front of the car. The frame rails should fit “inside” the shroud. Three #10 flat head, countersunk machine screws with washers and nuts fasten the front flange of the bonnet opening to the superstructure.

Two #10 flat head, countersunk machine screws with washers and nuts fasten each of the vertical shroud support brackets to the shroud. On the RH passenger side of the car, one of these screws, along with another, is also used to fasten the bonnet prop rod stay bracket.

Hood prop rod stay bracket

The front shroud was now fastened in place! I then attached the carb access panel and I was in business. The panel measurements are in the image below.

carb access measurements

Carb panel installed

I had a surprise visit from my 9 year old grandson, Tyler. As the photo shows he is getting ready to drive the “Bloody Beast.”

Tyler ready to drive

The two windscreen washer jets were installed on the shroud (would have been much easier to do before the shroud was put in place!) and connected with rubber tubing to the reservoir in the parcel shelf. I had previously installed the wiper motor, crosshead and rack, but I now needed to bring the wheelbox assembly up through the front shroud and secure them in place with the rubber washer, chrome bezel and chrome nut. This was not a pleasant job with all the wiring and underdash components in place, but after some struggling the job was accomplished.

Wipers

Chapter 18 – Cleaning and Trial Fitting

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April 18, 2004

Front Suspension Installation Continued 

I had the front swivel or king pins refurbished by Bruce Phillips at Healey Surgeons. I then followed the steps in the workshop manual:

Fit the new lower fulcrum pin into the lower trunnion being careful to center it, and then secure it with the two cotter pins. 

Placed the cork rings in their recesses on the lower trunnion and then fit the lower wishbone arms to the trunnion. Ensured that the half-moon cotters were correctly positioned and then greased and screwed the new steel bushes partially home.

Bolted the lower spring plate to the wishbone arms to establish proper positioning.

Threaded the steel bushes home evenly and then backed off a flat or two until .002” feeler gauge will fit between wishbone arm and the bush. Tighten cotters but was careful not to overtighten. The lower trunnion assembly should operate freely in the screwed bushes.

Place the cork washer on the top of the swivel pin and pushed it down to the bottom. Smeared swivel pin shaft with engine oil and placed the hub assembly on the swivel pin.

Fit a staybright washer followed by an oilite washer and then another staybright washer on top of the hub assembly on the pin. I soaked the oilite washer in oil overnight so that it would absorb the oil into its pores. 

Fit the upper trunnion and swivel nut. Nut should be tightened down (40 to 60lbs of torque) to allow a maximum of .002” lift. Pin should turn freely but snuggly.

Then released swivel pin nut.

Removed the spring plate from the wishbone arms to gain some flexibility in fitting the arms to the frame brackets.

Fit the two poly bushes to each lower wishbone link and pushed them into the frame brackets. 

Replaced the spring plate.

Inserted the fulcrum pins through the bushes and installed the second set of bushes through the frame bracket. Put the special washer with tab locator on the back of the bracket and lightly secured with a castel nut, not screwed home.

Fit the lever shock to the shock tower and insert mounting bolts. Fit the Putzke’s tube shock conversion bracket on the front of the lever shock with special long bolts and tightened lightly.

Front suspension left 6

Front suspension left 7

Placed the new upper trunnion bushes in place. I used poly bushes supplied from Udo Putzke.

Loosened the shock absorber arm mounting bolt.

Placed the upper trunnion with the bushes in position between the shock arms. Refit the fulcrum pin and tightened lightly after securing to the shock absorber.

Then set the assembly under proper load position. Accomplished by placing a two inch block (distance piece) under the shock arm opposite the rubber buffer.

Front suspension left 4

Tightened the fulcrum pin castle nuts for the lower wishbone arms in the frame brackets and insert split pins.

Tightened the four shock bolts to the shock tower plate. 

Tightened the upper trunnion fulcrum pin nut and place split pin.

Removed the spring plate and then used 3/8” threaded rod in seven inch lengths to hold new coil spring and plate in place. The lower mounting bracket for the Putzke tube shock conversion was attached to the rear lower wishbone arm at this time.

Front suspension left 2

Gradually tightened the rods until fully in place. Then replaced rods with proper spring plate bolts and tightened.

Installed new tube shock which required jacking up the shock tube slightly to align the mounting holes.

Front suspension left 5

April 24, 2004

Front Shroud Grill 

I couldn’t resist finding out how the grill would look in the shroud so I polished the original upper surround piece and installed it along with the Austin Healey motif on the shroud. The motif came from Hemphills and looked good. The upper surround uses 1/4” – 28 x 5/8” with two #10 – 32 x 1/2” screws on the left and right sides. The motif pieces has #8 posts.

Grill brow mounting

Grill brow

Grill exterior side mounting

Healey Shroud Motif

May 9, 2004

I borrowed Jeremy Turner’s cert nut pliers and installed cert nuts where the original fixed nuts were once located – light relay, insulation panels, dimmer switch, boot floor tie down staple and etc. Slow job but the nuts seem to work effectively. You drill a 9/32” hole for the #10 cert nuts and a 3/8” hole for the 1/4” cert nut. Then I installed the spare tire bump block on the left side of the boot wall. This block is supposed to use fixed nuts but I decided to use nuts with lock washers instead.

Spare Tire block

Motor Mounts – Removed the motor mounts from the motor to take to Jeremey’s for blasting and painting.

Motor Mount – Left 1

Motor Mount – Left 2

Motor Mount – Left 3

Motor Mount – Left 4

May 16, 2004

Front Suspension Again

Front Shocks – Installed right front lever shock. Left the rear bolts loose and fit the Putzke tube shock mounting bracket to the front two mounting holes. Inserted the two inch wood block spacer to set the height of the suspension. Loosened the shock absorber arm bolt and nut so that the shock will receive the trunnion.

Putzke shock adaptor – right front

suspension install – right

Control Arm Base Plate – Used 3/8” threaded rods to install coil spring with plate

coil spring install

Disk Brake Dust Shield – Attached dust cover assembly to the front left spindle axle with two short bolts at top. I installed with the caliper attached but it will need to be removed before installing the rotor and hub. Attached new stainless steel brake hose from pipe to caliper bracket. Secured the left steering arm to the back of the swivel axle and used the tab washer to lock both bolts.

Dust shield – left

Brake hose connection left front

Steering arm – left installed

Tab washer on suspension

Front Brake Rotors and Hubs – Fastened rotor disk to the hub extension with 5 nylock nuts. Placed bearing races in the freezer so they would be easier to install in the front hub extensions. Then inserted inside bearing race with proper driver with application of a hammer!, being careful to keep the race/driver straight. Turned the hub over and did the same procedure with the outside bearing race.

Inside front bearing race install

Left front inside bearing – 126-000 GHB105

SET 6 LM67048 – LM67010

20031255

Left front outside bearing – 620-234 GHB182

07196

20030322

Left front bearing race- 620-231

07087

20030522

Right front inside bearing – 126-000 GHB105

SET 6 LM67048 – LM67010

20031255

Right front inside bearing – 620-234 GHB182

07087

20030522

Right front bearing race – 620-232

07196

20020422

Front Hub Bearings – I followed directions from Bruce at Healey Surgeons and put 90 weight oil on the inner bearing and offered it up to the spindle. The oil will provide protection from damage due to bearing running dry but at the same time, not give a false reading when trying to shim the bearings.

I then placed the spacer (cone) on the spindle followed by the hub extension. I then put an oil filled outer bearing on the axle followed by the tab washer and castle nut. The seal and shims were NOT added at this stage. The nut was tightened down to seat everything and then the works were disassembled. It can be difficult to get the outer bearing and the tab washer off – I used a magnet that worked quite well.

I then put the inner bearings, the spacer and selected shims on the axle. Starting with the thickest one .030, then .010, .050, .030, ( one of each ). I then put the hub extension on the axle followed by the outer bearing, tab washer and nut. I tightened to 40 lbs of torque and determined if one of the castle nut slots lined up with the hole in the axle for the split pin. Need to take care that the shims are all the way up on the shoulder of the spindle axle so that they do not get mangled when the nut is tightened. The final proper adjustment is correct when you can tighten on the nut and the wheel does not show any reduction in ease of turning with no play. 

If it drags when you tighten the castle nut, then you need to add shims. If it is to loose, you need to remove the shims, When it is correct, re-tighten to the correct specs. At this point, the hub should be turning freely, with no end float and no pre-load.

Once you are satisfied that you have the bearings set up correctly, then remove everything. Make sure you keep track of the shims! Now pack the wheel bearings with wheel bearing grease and install your front seal (don’t forget this step). You need to place the spacer in the hub extension and bearings in first, and then reassemble unit.

Place the split pin through the hole in the spindle axle, and then pull one tab of the pin forward and bend it back over the axle end. Then push the grease cap on to the axle ( do not fill it with grease). Reinstall brake caliper.

Front Suspension Installed

Front suspension installed 2

 

Chapter 7 – Disassembly

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Front Shroud

Removed five cross head drive screws at the rear of the bonnet. Three screws with nuts must be removed at the front of the shroud at the bonnet opening. Two cross head screws and nuts also attach the shroud to upright posts. A third bolt and nut holds the prop rod bracket. Five pop rivets were drilled out along the scuttle. Two additional rivets must be drilled out along each side and where the rubber seal attaches to the scuttle. Two bolts securing the shroud to each frame extension in the front must be loosened from their nuts. The shroud can then be released from the rear and pulled forward.

Prop Rod Bracket Removed

Rivet Removal

Front Shroud to Frame Mount

Shroud Removed 1

Shroud Removed 2

Rear Body Panel (shroud)

The rear body panel is released by first drilling out 19 rivets along the lower lip. Thirteen rivets must be drilled out that hold the body panel to the luggage compartment frame. Two or three rivets must be drilled out on the side of the rear body panel where the wing fastens to it. Four cross head screws and nuts must be removed from the top lip of the boot opening. The rear body panel can then be removed. Care must be taken to not bend the small front lip on the aluminum panel at the front points.

Rear Shroud 1

Rear Shroud 2

Doors

Removed three posidrive screws holding the interior door handle. Removed four posidrive screws at rear of door by handle. Removed opening mechanism. Loosen phillips head screw in door handle accessible when the door handle is pulled. 5/16” nut on the door handle screw. Loosen 5/16” nut on the screw on the back of the door handle – not easy to get to! Door handle can then be extracted from the door.

Interior Door Handle

Exterior Door Handle Fastener

Door Latch

Door Fasteners

Removed side curtain bezel and retaining nut and chrome washer. Removed mid-door wood strip. One pozidrive screw on top center and two screws to the left and right on the bottom side. Removed the door strap (catch). 

Door Catch Mechanism

Interior Door Trim Panel Wood

Door Opener Mechanism Orientation

Remove door hinges. Four bolts into a securing plate for each hinge. Drilled small indentation into the top bracket to recognize it. On reassembly of doors mount outside door handle first. Then install mechanism so that the action arm is in the proper place.

Door Catch at Door

Door Hinges

Aluminum Door Hinge

Boot Lid 

Removed two screws and cup washers securing the handle/lock. Remove four bolts/nuts holding the lock/catch mechanism. Remove one screw holding the locking mechanism post. Lock surface was painted as were the screw tops so it was installed when the car was painted. The chrome lock and handle were installed after the car was painted because the locking post screw was not painted.

Exterior Boot Lid

Interior Boot Lid

Boot Lock Handle

Boot Lock

Removed the large cotter pin holding the rubber boot lid support rod. The rubber could then be removed as well. The head of he pin was located on the rod locator bracket side. A small cotter pin was removed from the support rod at the home bracket. The rubber grommet was then removed and the rod was detached.

Removed rubber gasket sealing boot lid.

Boot Rubber Seal

Boot Prop Rod Clasp

Heater Blower Assembly

Removed four nuts on posts through rubber grommets. Black ground wire connects to the angle pillar. Power is through a green wire with a brown stripe that plugs into a rubber junction. 

Removed the two heater blower mounting brackets. Two bolts each through wheel well arch. Large washers used on the tire side of the arch.

Smith’s Heater Blower

Blower Mounting Location on Frame Upright

Blower Mounting Rubber Grommets

Blower Motor Wiring Connections

July 28, 2002

Under Bonnet Components

Horns – Located on the left and right of center under the front shroud. Each horn is secured with two bolts fastened into small steel threaded plates. I don’t believe my horns or brackets to be correct as one was mounted on the vertical shroud support like later cars.

Horn on Shroud Upright

Horn Wiring Connections

Proper Horn Location Under Front of Shroud

Horn Mounting Bracket