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14/06/2009
First fit of the windscreen. The filler piece beneath needed a
lot of work on it to make it a reasonable fit. I don't know what
car Marlin made it for but it wasn't my Sportster!
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14/06/2009
Bolting up the windscreen under the scuttle. Actually a pretty
good fit here. You have to pack out the lower mount and mine was
reasonably symmetrical (3 washers one side 4 the other)
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14/06/2009
Little escutcheon covers
hole where screen support passes through scuttle. I had to polish
these myself as Marlin had forgot to do it. I made a gasket out
of some leather cloth to stop the water pouring in.
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14/06/2009
Grab handle for the nervous passenger... I made this from a standard
door handle from Screwfix, cut down and titivated with some heat
shrink and base made from nylon washers.
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14/06/2009
New wing bracket. The improvement is amazing. The
wing still bounces up and down- but not nearly so much - and no
sign of coming loose after the first strip of 40 or so miles.
Why Marlin couldn't have come up with something like this I don't
know.
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14/08/09
Dash eyebrow trim. I gave up with the U-shaped foam and just
made this from ply and covered in leathercloth. I may reduce
the width sometime in the future as it looks a bit heavy.
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14.08/09
Matching door top trim
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14/08/09
Fitting the tonneau. I fitted it at the rear first and then stretched
it using some cord tied to the front fasterners to get the position
correct. Masking tape has centreline.
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14/08/09
Final fitting. Not perfect but it will keep the rain off.
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14/08/09
You can zip out just the driver panel. Hopefully should keep the
rain off the rest of the car should you be caught in a shower.
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14/08/09
I had a brainwave. These curtail hangers help to support the tonneau
and stop it sagging. I think they will be very helpfull when drivng
with part ot the tonneau on.
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14/08/09
I bought this new rubber section from Woolies for the windscreen
closing panel.
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14/08/09
Fits much better than the simple U trim supplied by Marlin and
fills all the gaps.
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14/08/09
I wasn't happy with security of the bonnet so I have fitted a
switch tied to the alarm. I re-used a BMW door switch - fits a
treat!
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05/10/09
Wiper motor mounted on ali plate under scuttle. I had left the
BMW wiper wiring in place and it all worked first time (well second
time actually...)
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05/10/09
I managed to buy 2 wiper boxes and bundy tube (for a mini) from
ebay. I bought a third wiper box from mini spares. I cut n shut
the bundy tube to give me 3 pieces of the corect length. You can
see the join I made (silver soldered). I made a little jig to
remake the bell at the end of the tubes that had been cut. Total
cost - about £35.
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05/10/09
I made some mods to the heater box while I was at it. Elbow directs
the hot air to where you want it. The light (A GT6 number platre
light) illuminates the footwell when the door is opened.
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05/10/09
Ali drinks bottle from Wilco makes a fine washer bottle. I wanted
ali because of its proximity to the exhaust manifold.
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05/10/09
Non-return valve is essential if you do't want to wait 5 minutes
for the water...
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05/10/09
WW pump. This is a Lucas vane pump. The first one I tried from
Mafco was useless as it wouldn't self prime.
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