Cutting the rear chassis legs:In order to fit the body properly, the rear chassis legs need to be trimmed. Cut away a pie-shaped piece, about 15mm in width. See pictures. Placing the body on the chassis:The moment has come to unite the body and the under carriage. Please keep in mind that the holes of the body need to be lined up with the body strips, chassis tape, chassis clips and the chassis. Sadly most of the time this not the case and holes might need to be drilled or filed a bit. De body needs to be mounted with M7 bolts.
Please be aware of the fact that the body needs to be fitted slightly on an angle on the under carriage in order to give the alternator enough clearance to not clash with the front of the body. Taking measurements is useless!
- Place the chassis clips or J-clip nuts on the chassis. (see drawing)
- Stick the chassis tape on to the chassis (see drawing)
- Put the body on the chassis. Lift the body with two helping hands and slide first the rear over the chassis. Pull the body to the front until it slides over the rear axle. Please be aware that no fuel or brake lines get stuck between the chassis and body. The body is positioned correctly when the body sits just in front of the t-link of the brake lines.
- Use the stainless body strips to prevent unwanted tension in the polyester. Please be aware of the fact that the left and right body strip or not similar.
- Puncture a hole through the chassis tape to make it possible to secure the bolts in the chassis. You can use a drill and let it turn counter clockwise to create the holes.
- When you have made sure that the connection between the chassis (3) and the floor of the body (6) are nicely sealed by the chassis tape (5) you can tighten the M7x25 bolts (1) to the J-clip nuts (4). Use a M7 sheet-metal ring between the bolts and the stainless steel body strip (2). Start with the 2 front and 2 rear bolts and work your way to the middle. This will prevent not lining the body up with the chassis. The two bolts on top of the petrol tank bracket need to have the original large sheet-metal rings to spread the tension in the polyester.
- The bolts at the rear of the chassis are the last ones you need to secure. These bolts are in the spare wheel pocket in the boot. There is a possibility these holes do not line up with the chassis. When this is the case, just drill some new holes. The old holes can be filled up with kit or polyester.
- There is a possibility that there is a hole at the front of the body strip just behind the first bold. This is normal and can be sealed with kit to keep out water.
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