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Hinges
Attach the bonnet to the body with the hinges.
- Using a little dent in the body to mark the spot, drill the holes in the body to attach the hinges (Ø8.5 mm). Bear in mind that there is a left and a right hinge. The bottom of each hinge indicates the side on which it should be used. It says RV, LA for the right front and left back, and RA, LV if the hinge if meant for right back and left front. This is seen from the driver’s perspective, so the passenger’s side is indicated by ‘right’ . If you do this the other way round, there is a chance your gel coat will get damaged when the valve is opened, or the hinges might break. The hinges will then be out of warranty.
- Draw the position of the headlight bracket on the bonnet and file a cavity for the bracket.
Drawing the Burton logo and mounting the grill:
The placing of the logo has already been indicated on the bonnet; the oval logo falls exactly on the notch above the opening of the grill. Depending on which logo you have chosen, it is assembled with two M3 bolts or with 2 wires that are attached to the logo. At the top of the grill, two holes have already been drilled so that the placement of the logo on the grill has already been decided.
- Place the logo neatly on the bonnet in the middle of the notch. Clamp the logo temporarily.
- Drill the two attachment holes with a diameter of 3 mm.
If you have chosen the ‘open’ bonnet logo, which is attached with two threads, carefully measure these holes or make a paper mould.
- The attachment of the logo is also the attachment of the grill.
- Attach the logo with two M3 bolts and jam the grill against the inside of the bonnet. Do not use the mounting kit yet.
- Make sure the grill lies straight in the bonnet.
- Drill two 5.5 mm holes at the bottom of the grill through the polyester.
- Remove the grill and logo, and then fasten it using a bit of Sikaflex mounting kit on the top and bottom of the grill.
- Attach the grill with the logo and two M5 round head bolts to the polyester and at the same time to the lock catcher on the inside of the bonnet. (Thus, the order is: M5 bolt, washer, grill, polyester, lock catcher, washer and locknut)
Make sure the lock catcher is neatly attached to the polyester; if not, scour the polyester.
Mounting the bonnet lock to the front:
- Attach the control lever to the bonnet lock. There is a spring at the bottom of the lock, remove it from the 5 mm hole. An M5x12 bolt is used for this hole to attach the control lever at the same time. The spring will be inside the small hole in the control lever. See the picture.
- Close the bonnet and mark the place on the front where the lock catcher comes. This is the middle position of the lock.
- Draw exactly the middle between the two holes on the wind hook.
- Place the wind hook temporarily on the inside of the front and keep the top of the wind hook equal to the polyester.
- The drawn centre of the wind hook should now fall equal to the centre of the lock catcher.
- Draw the holes and drill them (Ø6.5 mm).
- Mount the bonnet lock to the front.
- Stick the bolts through the entirety. (Order: M6x30 bolt, sheet-metal ring, polyester, wind hook, bonnet lock, sheet-metal ring and locknut)
- Close the bonnet and check whether everything clasps together. Adjust where necessary.
- If everything closes properly, the bottommost third hole can be drawn and drilled. This one will later by covered by the license plate. This hole is 48 mm below the holes for the bonnet lock. Attach with an M6x12 bolt.
- As extra reinforcement, you should, now that everything closes properly, glue the grill with Sikaflex. Do this on the top as well as on the bottom side.
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