Demisters

Fitted the demisters as figured that would be an easy job as the holes have already been cut out .
Not quite that easy as the hole centres didn't line up and the holes weren't wide enough drilled the holes out to 5 mm to give me a bit of room and filed the slots out and it fits two issues I am not happy with
1 the white fibreglass can be seen though the slots which stands out too much on a black car and
2the body is curved but the demisters are straight this means they fit nice at the edges tight up to the bracket but I have a gap in the middle .

demist slots look good from this angle

going to try to build up the gap with black silastic which may sort out the first problem as well






 

Battery cables

Had a bit a time today so fitted the battery cables I copied Dales post and fitted the Positive at the bottom ,although my set differed from his as only had rubber protectors on the engine side ( will need to clarify that with Andy )
Also the main wiring loom supply that I fed in above the heater what seems like an age ago needed to be fitted to the positive as well which needed filling out to fit !
another little job off the list. also fitted the heater plug at the same time ,The heater is three speed and the wiring is for 2 speed using the diagram on the side of the heater went for lowest and highest ( can always change my mind )

Batt cables from the inside showing the main loom feed and the now wired heater plug

Also dropped in the battery box to test for fit ready to bolt though the floor on next visit .

seems to be too many holes just for a bat box more reading required  

 

Washer jet

looked at the kit and two jets are provided but copied a lot of other people and went for just the 1 as it is twin jet and how much rain use am I going to see ( famous last words )
found the centre of the car and marked 20mm  in from the bonnet copied from other blogs and noticed that the windscreen stay was 3 mm off the centre line . After deliberation and re checking my measurements it is the windscreen that was not quite plumb, assuming this is due to the windscreens being hand made. Decided to stick with the centre line as the stay bracket wont be seen because of the rubber .

Jet fits nicely

 

Fuel Cap

I opted for the Aston Martin type fuel cap and it comes undrilled but had pilot indents on the underside.
Drilled these 4.5 mm to accept 4mm countersunk bolts which then needed countersinking from the top .
This was a challenge in itself  as the countersink (from screw fix) was too wide to get square on to the holes so with a make shift lathe ( drill in the vice and angle grinder !!) made it thinner so it now fits

Drilled out and countersunk

then it was just a simple job to fit the unit to the car but wanted to make sure that the cap was the right way round so ,,, fitted the cap with all the gaskets as clearance s close tightened it down and placed it on the car so it was facing were I wanted it to then mark the holes

placed on the car at the angle I wanted

I then drilled a 5mm hole and tapped it out 6mm to place a grub screw in the back ( as picture above) so it could not move over time .

Marked the holes and drilled out 5mm so I had a bit of error factor and fitted it looks good .

finished cap

Wipers

Tackling the wiper mounts today ,The outer edge of the rubber washers were marked at 415 mm from the windscreen stay and 5 mm from the screen rubber and the eliptical spindle holes were marked on to masking tape using the inside of the rubber washer as a guide. The centres of the holes were established and marked only to find that they were marked already by GD .Oh well at least I was right with my markings . I then checked that the distance between the holes was the same as the assembled wiper mechanism and it was within  2 mm which I figured I could lose by bending the tubing to follow the curve of the body



All set to drill my baby  

 Drilled the holes with a small drill first as expecting it to bite which it did
after that I drilled  the rest of the holes with the drill going backwards ( always amazes me how that still cuts )
once I had got to 13mm I set to with a file for the final touches .

Once  the hole right the GD manual says that the spacer has to be cut down measured this and decided it was 5mm to long .

original spacer

Quick drive to one of Steve's mates and a 30minute lathe job later the spacer was right .

5mm shorter

Fitting it all was a lot more fiddly than I guessed it would be due to weight of the motor so took the motor off and just fitted the tubes with the idea of threading the motor though later.

What a pose

That all went well  and all lined up very well slid the motor cable up though the tubes and turned the wiper spindles to feed the cable though .all went easy .secured the motor with the bracket and after reading the manual noticed I should have put a piece of rubber between the motor and frame (did wonder what that strange bit of rubber was )

fitted and happy

motor secured (with the rubber)
 

 

The park position of the motor will need to be checked once they run as the wipers should park on the drivers side (which may need to be altered later .

 

another job off he list.