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Fitting Print

Brittle
Image 7You'll also need to remove the little plastic "saddles" that support the lock actuator rods. They're in two parts, with a collar pressed into a hole in the metal, and the saddle (looking like a miniature rowing boat rowlock) pushed down into it. This plastic will probably have got very brittle, and it is easist to angle-grind a hole in the outer face of the frame so a screwdriver can be  used on the parts from behind to gently push them up.

Not SymmetricalImage8
Likewise, the rear window sealing strip holder is best fitted before the frame is assembled. You may have to remove it again temporarily, to allow the lock to be fitted into the frame. You'll need to drill the (2mm) fixing holes yourself. Note that the holder isn't symmetrical and the longer lip needs to face towards the outside (rear) of the vehicle, in the angle of the lower frame. Similarly, drill and fit the top rain gutter to the top frame, but remove it again before assembly. Start from the centre and work outwards, as you are forcing it into a curve. Now you can start to build the top and sides together. Lay a blanket on the table (worktop) to protect the powder coating and offer up the pieces, having first cleaned up any rough edges on the mitre with a file.

Cross-thread
Fix the top of the side frames together - the instructions with the kit warn that the screw in the top frame won't lie flat but it will be partly hidden by the top rain gutter. Take great care not to cross-thread the machine screws: you're going into an angled end, and the aluminium is soft. Before final tightening, lay the frame on a flat surface to make sure its not warped.