Specifications

BODYSHELL
Access for this operation is from the
underbonnet and underside of the bodyshell.
However, before welding this bracket into place,
the bearing housing itself should be modified to
fit the bracket correctly. This will entail cutting
away a portion of the bearing housing flange just
below two of the attachment holes. Three holes
should then be drilled through the housing and
bracket, using the housing as a template. Three
nuts should then be tack welded to the rear face
of the bracket. This will enable easy attachment
of the bearing housing to the bracket after it has
been welded into position.
This bracket is shaped to fit the exact
position required, and when measured should be
65mm rearwards from the face of the steering
rack mounting plate. This should then exactly
locate the bracket in its correct position, which
when measured should be 65mm rearwards from
the face of the steering rack mounting plate.
NOTE: This is a delicate operation as the
positioning of this support bracket is crucial for
satisfactory gear linkage operation.
The aperture in the steering rack mounting
bracket where it meets the lower chassis region
must also be increased in size along the lower
edge by removing 10mm from this flange. Seam
weld the section after removing this metal.
NOTE: This MUST be carried out at this stage
to give adequate clearance for the revised
gearchange mechanism.
Refer to the diagrams for guidance.
The bodyshell, now free from all unwanted
items, can be cleaned off in readiness for the
seam welding and strengthening operation.
All
exposed body seams throughout the bodyshell
that are actually spotwelded in the production
process require further "stitching", preferably
with a MIG-type welder. This entails making an
additional 25mm run of weld every 35mm along
EACH visible body seam throughout the
bodyshell, and applies equally to the underside,
underbonnet and bulkhead areas. However, the
lower flanges of the front chassis rails where they
j oin the inner wheelarch require special attention.
Using either a spotweld cutting tool or drill bit,
carefully cut through ONE THICKNESS of the
seam in between each production spotweld and
fill hole with weld, forming a "puddle weld". In
addition to this operation, certain areas require
further reinforcement by welding on additional,
specially profiled mild steel plates. These are
supplied in the kit, their profile following that of
the original area and by double skinning give the
additional strength required. Final positioning
will be apparent when the plates are placed
against the designated area, and should not
require further modification prior to welding in
place. The inner pivot point for the bottom
wishbone can be further strengthened by welding
a large metal washer onto the forward face. The
hole through the pivot should then be opened
out to 12mm, to accommodate the larger
diameter bolt. The bodyshell also has in excess
of 20 drain holes in the floorpan, these must be
closed off by welding the circular discs supplied
over the holes. The side lift jacking point can
now be fitted. Place the strengthening plate
against the sill and mark the centre of the hole
required. This should be 22.5cm rear of the
front wing joint on the sill. Cut a 35mm. hole
through outer skin only. The inner 35mm. hole
should be formed with its centre 55mm. above
the floor panel, so that when the tube is
introduced it is not parallel to the ground, but
slopes upwards towards the inside of the
bodyshell.
The tube can now be inserted
through the plate and sill, before finally welding
into place.