Chapter 55 Restoration Assembly, Week Twenty-Five 6/4/2007

Installing the seat belts was fairly straight forward. I had drilled holes earlier for the mounting kits. I was going to go with the seatbelt/shoulder harness assembly sold by British Car Specialists, but ultimately decided to go with the “vintage look” racing belts sold by Moss Motors. These belts work beautifully with my interior color combination! The shoulder harness kit would have been the best call for safety, but the belt retracting mechanism to be mounted on the rear quarter panels just looked too contemporary. I am pleased with the result!

Seat belts

I had been dreading a job, that as things turned out, was not as challenging as expected. I needed to locate and install the #6 stainless screws with trim rings that secure the rear jump seats. I was scared to death that in doing so I would damage the beautiful leather trimming job done by Heritage Upholstery and Trim.

To prepare for installation, I first glued marine class rubber weather stripping around the rear seat tubs. I peeled back the leather on the underside of the seats, located the original screw holes, and carefully punched holes through the leather. A previous owner had used oversize screws to mount the seats and the holes in the superstructure were bigger than they should be for #6 screws so I had the holes filled by Jeremy Turner at Maple Hill Restorations while bodywork was being completed. Therefore, this job required locating new holes in the superstructure and drilling them.

I had Judith, my wife and able assistant, sit in each seat to press it down to the mounting platform and position them as well as possible. I then marked each hole location. I used a 1/8” hollow punch to remove carpet, dynamat and aluminum insulation from each hole location and drilled the holes in the superstructure. Everything turned out great and the installation appears as original. I really don’t care for the look of the stainless screws in the leather, preferring the BJ8 seats that have studs to secure the seats, rather than the screws, but I decided to remain original on this matter.

Rear seat fasteners

Rear seat fasteners

I had never finished the installation of the courtesy lighting in the boot, so it was time to return to that task. I used a rear license plate lamp to supply light and modified the chrome casing to permit more light to enter the compartment. The lamp was wired to the courtesy lights in the interior, so with a flip of the toggle switch or with a click of the remote control “clicker,” the boot lamp is activated.

Boot light

I can’t say why I have not installed the brake and clutch master cylinders and pipes before now? I secured two new master cylinders into the pedal box with the four 5/16” hex head bolts. Aluminum packing shims were used on both master cylinders.

Master Cylinders & Lines

The LH and RH bonnet opening support plates were attached to the frame upright and the brake reservoir was clamped into its bracket on the LH post. The two hydraulic pipes were fitted and the double clamp securing the pipes to the inner fender was screwed in place.

RH Bonnet Opening Support Plate

LH Bonnet Opening Support Plate

Brake Reservoir and lines

Chapter 13 – Cleaning and Trial Fitting

March 22, 2003

Rear Seats 

The rear seat pans were very rusty and pitted to some degree, but given that they are completely covered by upholstery we decided to reuse them. The bottom exposed side of the seats was painted with a rubberized undercoating paint. 

Rear Seats 1

Rear Seats 3

May 16, 2003

Canadian Delivery! 

Martin Jansen delivered the healey from his shop in Canada on the back of his pickup truck! Big day!

May 16 Arrival Day from Martin 1

Rough Body 2

Rough Body

Rough Body 3

The frame and superstructure looked great. The fit of the wings will have to be improved upon. Door fit is pretty good, but will also need additional work. New edges were put on the rear shroud and rough repairs to the front shroud lower panel were made as well as around the rear shroud taillight area. Seeing the interior panels without rust is hard to believe, but they sure look good now! One disappointment is that mounting holes for a number of things are not located on new panels installed by Martin. Seat rails, exhaust mountings, insulation panels and etc will need to be aligned and drilled.

Firewall 3

Firewall 2

Boot 1

July 15, 2003

Maple Hill Restorations 

After consulting with Jeremy Turner from Maple Hill Restorations we have decided to completely assemble the car while in primer to be ensured that EVERYTHING fits properly. This will prolong the project, and will probably lead to some short term frustration, but should also minimize problems with assembly once body work and painting is complete.

My first step is to determine proper fastener sizes and replace all original hardware with stainless steel, with the exception of higher load locations such as shock absorber and other suspension bolts. Those will be replaced with new grade 8 zinc plated hardware. Then we installed all of the rubber grommets in the firewall, footwell and other locations.

The Scientist at Work

Chased Threads and rubber grommets

Installed pedal box

Steering Bracket and Brace

Boot Grommets – The grommet for the battery cable and other bulkhead grommets were installed in the boot. The anti-theft battery switch and bracket were also installed.

Boot grommets

Battery box and switch

Bump Box

Boot Tire Buffer

Insulation Panels – Some of the mounting holes for the heat insulation panels on the firewall and footwell were also not drilled. We located the proper locations, drilled the holes and mounted the panels without difficulty.

Insulation 1

The Oil Pressure Line – The line was located and installed although new clips will be ordered.

Oil Line

The Dip Switch and Parcel Tray – These components were also located and installed. Note the original water bottle.

Parcel Tray & Bottle

Installed dimmer switch

Radiator Brackets – The brackets were cleaned and painted and were installed on the crossmember, and the painted air intake flange.

Radiator Mount 2

 

July 23, 2003

Hardware Reassembly

Door Staps – The original door straps (catches) were cleaned, re-zinced and installed on the door pillars.

Door Strap 1

Door Strap 2

Bonnet Hinges – The bonnet hinges were cleaned, primed and new stainless hardware was installed, and then mounted to the car.

Bonnet Hinge 1

Bonnet Hinge 2

March 22, 2003

More Cleaning 

Bonnet Latch Hardware – Disassembled and cleaned the bonnet latch assembly and the bonnet opening rod assembly for Jeremy Turner to media blast and paint.

Bonnet Rod Spring

Bonnet Rod Bracket grommet

Bonnet Latch A

Bonnet Latch B

Bonnet Latch C

Also cleaned the bonnet rod clip, the catch bracket, two safety latches, the brake reservoir bracket and two shroud brackets.