Making the most of the sun

The car hasn’t moved for a couple of months for various reasons. And I’m in two minds about renewing the tax at the end of September. However There’s a factory open day on October so I’m thinking of switching over to monthly tax for at least 1 more month. 

It’s glorious weather in Shropshire today so I nipped out for a quick lunchtime run to Much Welnlock and Ironbridge, via Buildwas on the way back. 

  

Roll Bar

The factory spec car comes with a rather chocolate roll bar. It’s neither tall enough or strong enough to be an effective safety device. Luckily there’s an official factory replacement that really should be standard issue. The chassis already has the additional fitting points so I set off on this installation hopeful of an easy job. This was at the start of August when the sun was still about!

First up, here’s the original which is lower than the new seats I recently installed.  
And the new bar for comparison

The old bar was easily remove via a single old at each side. Then as the new bar has 3 bolts per side I had to drill the bodywork to match the pre drilled holes in the chassis. Note that the boot box has to be removed for access, then cut to fit the new bar.

Once the new bar is bolted in the bracing stays can be trial fitted and the bodywork trimmed to allow them to be fitted properly. They bolt to the new bar and also into the chassis either side of the fuel tank.

bolts fitted to the chassis

Then comes the hard part. Trimming and re-fitting the boot box. This was a horrible job as you need to trim it sufficiently to allow it to fit past the new bar and rear braces. Sounds easy. It took an age of trimming and test fitting and trimming and sanding and in & out with the braces. Lots of reaching and bending. I was broken at the end of a soldid 8 hours of graft in the baking sun.

Totally worth it tho 🙂

Whilst the boot box was out of the way I checked the fuel tank over. All ok but I do need a new fuel sender as suspected. It’s a cheap part but to fit it I have to remove the boot box and rear braces again. A job for another month when I’ve recovered!

I must also mention the guide I used for the job. Disappointingly the new bar shipped with no instructions at all and none were forthcoming when I asked. Not really good enough. So many thanks for this guide.