Bodywork

Side screens

Side screen are mounted to aluminium brackets via a threaded hole and cut screw.
Screen mount

Aluminium brackets cut & drilled.
Side screen bracket

Many, many hours of polishing later brackets ready for mounting.
Side screen brackets polished

All done.
Side screen done
Mounted bracket up close

Bodywork

Paint!

It’s been a long time coming, but we finally got the Sportster painted and reassembled and here’s the result:

Chassis

Vents and washer bottle

Demister vent tubing made out of some drain pipe<br />

Demister vent tubing made out of some drain pipe

Scuttle vents, these are from a mini with some stainless mesh added.<br />

Scuttle vents, these are from a mini with some stainless mesh added.

Plastic tubed sprayed black and glued to scuttle. Some black rubber acts as a connector to the pipe that came with the heater<br />

Plastic tubed sprayed black and glued to scuttle. Some black rubber acts as a connector to the pipe that came with the heater

a view of the rubber connection on the heater vents<br />

a view of the rubber connection on the heater vents

Centre console covered with heater vent built in to direct the warm air at your feet.<br />

Centre console covered with heater vent built in to direct the warm air at your feet.

Scuttle on with heater pipes attached<br />

Scuttle on with heater pipes attached

Vent pipes attached to scuttle<br />

Vent pipes attached to scuttle

Bracket to attach screen wash bottle<br />

Bracket to attach screen wash bottle

Screenwash bottle holder<br />

Screenwash bottle holder

Screen wash tube going through the firewall<br />

Screen wash tube going through the firewall

Screen wash bottle and motor installed.<br />

Screen wash bottle and motor installed.

12V accessory socket for the GPS<br />

12V accessory socket for the GPS

Bodywork coming together<br />

Bodywork coming together

Sorting out the wiring under the scuttle<br />

Sorting out the wiring under the scuttle

Sorting out the wiring under the scuttle<br />

Sorting out the wiring under the scuttle

Wiper motor and connections.<br />

Wiper motor and connections.

Bodywork

Getting there

I was hoping that the car would get finished today, but as always there were more and more little things to do!

The centre console now has bracketing to hold it securely in place, the tub is secured and positioned right for the doors. The doors with re-enforcement brackets are on but not adjusted yet. The demister vent connections are nearly done. I tried setting up the amp with the scope but either them is chucking out some funny signals or the scope is on the blink. Headunit has clean output to setting 60 of 62. Higher than 60 and you get a tiny bit of distortion creep in.

Once the demister vents are sort the scuttle can go on and the doors adjusted. After that it’s just bonnet side panels and head lights.

Bodywork

Centre console, and rear end

The centre console coming together, this will also act as a duct for heater down to your feet. There’s also a 12V supply in the side of it for the all important sat nav (or I’d get very lost all the time):

Here is is from a higher vantage point:

The 77MP’s styling fits the car quite well:

All the wiring needs a final tidy up after settings are finalised.

Door hinge bracket, one of four. The metal the door is bolted to is far to thin, it flexes all over the place. Hopefully these will add enough structure to fix this.

Exhausts bolted up, bumpers fixed in place, rear lights in place and working. Just needs the other wing and a number plate.

Interior

Fuse box & speakers

Mk 2 fuse holder bracket<br />

Mk 2 fuse holder bracket

This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.<br />

This bracket also holds the wiper motor. The clamp has been moved up a bit to reduce flexing.

The centre console is taking shape with a small recess to keep your glasses.<br />

The centre console is taking shape with a small recess to keep your glasses.

Managed to find some room to fit a speaker above the steering column.<br />

Managed to find some room to fit a speaker above the steering column.

There's some sides and top to try and keep the front and back separated as much as possible.<br />

There’s some sides and top to try and keep the front and back separated as much as possible.

Once the dash is in you can't see it any more.<br />

Once the dash is in you can’t see it any more.

Interior

Speakers, hazards and other stuff

Nose cone and centre console

Nose cone fitted.

hmm pretty colours

Starting to piece together the centre console

Two supports cut and shaped to get the angle of the radio correct with enoughclearance for the rear of the radio.

Radio supports glued.

Just need to make up some sides to hold the midbass speakers under the dash.

Bodywork

Interior and rear lights

Dash board re-trim without glove box (wiper motor in the way)<br />

Dash board re-trim without glove box (wiper motor in the way)

Rear of re-trimmed  dash showing pod for speaker<br />

Rear of re-trimmed  dash showing pod for speaker

Divers side behind the dash<br />

Divers side behind the dash

Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.<br />

Test fit on car, the mount holes needed drilling out as the paint had filled them a bit.

The speakers could do with a grille mesh to finish them off but other than that it is coming together.<br />

The speakers could do with a grille mesh to finish them off but other than that it is coming together.

Rear lights installed with new waterproof plugs - a bigger job than you might expect!<br />

Rear lights installed with new waterproof plugs – a bigger job than you might expect!

Chassis

Exhaust Hanger Mark 2

Mark 2 exhaust hangers, these use the rubber mounts from a BMW 840Ci Sport. There is 3mm steel plate than connects the exhaust boxes to the hangers.

A new bolt is welded in on the right side of the hanger, the other is the one form the fuel tank strap.

Driver side bracket, this one has some stress on it but the rubber mount is off a 12 year old car so the rubber has gone soft. A new pair will need to be ordered to finalise this.

The plates need a coat of paint and this can be marked as done.