3.1. START OF THE DISMANTLING

You start with the removal of the following parts. [Parts with a (B) behind their identification are required for the Burton. Parts with an (O) are optional. If there is neither one of these two markings behind the dismantled item, you can be sure it is not needed for your Burton]

In order to prevent unnecessary damage and /or destruction of nuts, bolts, bleeding screws etc, it is more than wise to apply WD40 (or any another penetrating lubricant) abundantly on the respective threads and give it time (several hours at least but a day or more is better) to do its work. This way you will prevent any irreversible damage. This specifically applies to the brake bleeding screws.

· Keep the bonnet half opened and push it out of its rail, either to the left or the right. Subsequently remove the license plate (B). Keep the bonnet stay (B) as well as its seating rubber (B).

· Battery (B). In order not to create any short circuit, you always need to disconnect the battery first. Do so by first disconnecting the negative (=ground) pole followed by the positive pole. Never do this the other way around! Every battery has toxic as well as aggressive contents, so always keep it upright. In case the battery is beyond its “best before” date and needs to be disposed of, do so at your local chemical waste depot. Batteries have a limited shelf life, so if the donor car has been idle for several years, its battery will be unusable due to corroded and/or bent plates. If you intend to re-use it, check it with the appropriate test tool or have that done at your local garage.

· Back doors: open them until they are at a 90-degree angle with the body and push them out upwards. Preferably, remove the door rubbers and the door catch first.

· Front doors: undo the hinges by removing the four bolts at the door side.

· Boot lid: remove it by opening it and pushing it out sideways.

· Front wings: undo their four bolts, disconnect the wiring and remove them together with their triangular panels.

· Front seats: slide forwards out of their rails. Be aware of the possible locking pin.

· Rear seat (B): press and hold pins down then tilt seat forwards, after which it can be removed.

· Get rid of the floor mats

· Wiring harness (O). Check the harness for possible damage and absence of modifications. Undo all connections and label them, so later you still know which connector was attached to what component and where on that component.

· Remove the steering column. Some cars have an anti-theft device. If so, remove the part clamped around the steering column (2 small Allen bolts). Then undo the bolt (B) and clamp (B) at the extreme bottom of the steering column and remove the steering column assembly by pulling it out with brute force. Only the bolt and clamp will be re-used, however the rest (=steering column plus steering wheel) can be useful when having to move the rolling chassis, so hold on to it a little longer.

· Undo the accelerator cable at the carburettor side and pull it inwards (out of its sheath)

· Choke cable: same as the accelerator cable.

· Clutch release cable: shorten the length of the outer sheath by adjusting the adjusting screws. Subsequently undo the inner cable at the pedal side.

· Speedometer cable: is connected at the rear of the gearbox on the left hand side. First undo the fixing bolt (spanner size 11mm), then pull the cable assembly out of the gearbox.

· Gearshift handle: undo on top of the gearbox. Save the rubber ring (B). The clamp (B) at the bottom of the gear stick will be re-used.

· Hand brake (B): undo at the metal strip between handle and hand brake lever, subsequently pull the complete handle inwards.

· Heater controls (B): undo at the left hand heat exchanger and keep all parts.

· Now is the moment to undo the central wheel hub nuts of both front wheels. Once the brakes no longer function this becomes a lot more difficult. Remove the wheel, remove the cotter pin from the hub nut, have someone else engage the brakes and undo the hub nut (32 mm).

IMPORTANT: in order to prevent unnecessary brake line replacement, spray all nipples with plenty of lubricant (WD40 or the like) and let them soak for a while before even trying to undo these connections.

· Undo the brake pipes (B) from the master cylinder (B). Preferably do so by using a special hexagonal brake pipe spanner in order to minimize damage to the brake pipe nipples. Use standard M8 bolts to close the openings in the master cylinder. That way no dirt will enter during the assembly period.

· Exhaust (B): undo at the front silencer as well as underneath the front- and rear seat. Cut the rubber bands if necessary.

· Disconnect the wire (B) for the petrol tank gauge at the petrol tank near the left rear wing.

· Remove the headlamp height adjustment by first removing the cotter pin and then turning it counter clockwise at the headlamp joint.

· Disconnect the claxon or horn (B).

· Headlamp fixing: keep all convex washers (B) as well as all associated nuts (B).

The following parts have to be removed from the body in order to be re-used on the Burton:

· Citroen identification plate on the bulk head (B). Carefully drill out the rivets.

· Heater controls plus cabling (B). Undo two bolts under the bulkhead and remove the controls plus cabling.

· Windscreen wiper motor (B). If you intend to equip your Burton with a windscreen wiper mechanism, you will have to return the wiper motor as an exchange part to the Burton Car Company. In the Netherlands, a complete windscreen wiper system is mandatory when the full size front windscreen is installed. The small, hardened steel axle (approx. 2 cm long with a bend) has to be returned. The rest can be disposed of.

· Master brake cylinder (B) and pedal assembly (B) should be removed. First, take out the brake fluid reservoir (B) by popping it out of its connecting rubber washers, using a flat screwdriver. Remove both the master cylinder M9 bolts as well as those for the pedal assembly. Once undone, both the master cylinder and the pedal assembly should be removed by pulling the complete assembly inwards. Now remove the clutch cable from the fork after which the complete pedal set can be taken out of the passenger compartment.

· License plate (B). Remove the license plate from the body.

· Ignition coil (B) and its plastic mounting brackets (B) plus the nuts and bolts used to fix them (B) should be removed from the headlight bar.

· Both the handbrake lever (B) and its guiding system (B) are needed for rebuilding. The handbrake guide has to be removed by drilling out the spot welds.

· Save the folding windows (O) along with their hinges (O) if you intend to equip your Burton with a hard top.

· Complete set of seat belts. Although the actual belts cannot be reused, their fitting bolts can be reused to mount the Burton seat belts. Beware: in the Netherlands, you are only allowed to install and use seat belts in your Burton if the Burton is equipped with a roll bar.

· Speedometer, switches and indicator lights, assuming you want to re-use them in your Burton (O)