andy couchman Posted July 7, 2003 Share Posted July 7, 2003 Am just about to fit a new boot cover to a long cockpit live axle classic chassis which has an FIA rollover bar (the sloping forward type). The boot cover has a steel strip in it. Do I need to remove this (think I do) and does it have the full harness bolts on top (think it does) and the end of the rollover bar on top too. That looks roughly right but would hate to make a mess of the shiny new cover on the shine new rebuilt chassis. Yours confusedly. Andy Couchman Link to comment Share on other sites More sharing options...
mav Posted July 7, 2003 Share Posted July 7, 2003 Andy, The bolts for the harness DO go through the strip. Mahe sure you measure twice and drill once! Link to comment Share on other sites More sharing options...
Gridgway Posted July 7, 2003 Share Posted July 7, 2003 I have previously removed the strip (by unsewing), drilled the holes in it and put it back. Then got er indoors to sew it up again. Graham Link to comment Share on other sites More sharing options...
Leadership Team SLR No.77 Posted July 8, 2003 Leadership Team Share Posted July 8, 2003 Definately a good move - swarf in the sleeve where the strip sits is not good Stu. Link to comment Share on other sites More sharing options...
scooby dooby doo Posted July 9, 2003 Share Posted July 9, 2003 why would you want to remove it 🤔 its there for a purpose (so the boot cover fits properly round there). and swarft is preventable by careful drilling and perhaps a light file afterwards... HOOPY R706KGU Hoopylight R Link to comment Share on other sites More sharing options...
Julian Thompson Posted July 9, 2003 Share Posted July 9, 2003 I fitted mine with no metal strip.....I assumed that you didn't use it if you were fitting harnesses.. Link to comment Share on other sites More sharing options...
Graham Sewell Posted July 9, 2003 Share Posted July 9, 2003 As mav says - measure twice, drill once. I would add that you should drill undersize and then use a circular file to get it 'just right'. Method #1 was to put masking tape underneath the boot cover, press down on the harness points to get the correct location and then drill and fit ONE bolt. Then remeasure each of the remaining bolts in turn. For general location, it helps if the poppers are already in place so that you can ensure that the strip is central on the bulkhead. However, if the poppers are not in place, treble check everything is level before you make the first hole in either the strip of the bootlid sides. My last boot lid came with no poppers in place and it took several dry runs before I hade the first hole to ensure that the lid was central on the bulkhead and that there was enough material hanging over the dges to fix the poppers to. If you have a spare wheel, do not bother with the two poppers on the 'flap' - the velcro holds that in place well enough - otherwise you'll be removing the spare wheel every five minutes. Low tech luddite - xflow and proud! Link to comment Share on other sites More sharing options...
scooby dooby doo Posted July 9, 2003 Share Posted July 9, 2003 work from the middle outwards as well - or you may get a bulge. HOOPY R706KGU Hoopylight R Link to comment Share on other sites More sharing options...
Julian Thompson Posted July 9, 2003 Share Posted July 9, 2003 Just looked at mine and it looks absolutely perfect with no metal strip. And think of the weight saving 😬 😬 Link to comment Share on other sites More sharing options...
CharlesElliott Posted September 17, 2003 Share Posted September 17, 2003 Did people use the existing six holes in the chassis bar that the harnesses bolt into for popper locations? Two of these (one each side) are very close to the harness bolts but it looks as if there is enough clearance. (The reason I ask is the assembly guide says - remove metal strip in boot cover leading edge and discard. Bolt the harnesses through the boot cover. Use the two predrilled holes 1.25" either side of the centre as popper locations. Don't use the other predilled holes (one between the harness mountings and one just outside the outer one) - drill two new holes in the centre of the harness mountings and use those. All seems a bit unecessary to me - but then I may be missing something 😬) Charles --- My Caterham Academy 2004 Diary Link to comment Share on other sites More sharing options...
tony pashley Posted September 17, 2003 Share Posted September 17, 2003 Andy - I think some of us are confused as to whether you want to remove the aluminium strip for all time or just in order to drill it (as Graham did)... I'm with Hoopy - why? However, I'd carefully cut the harness-bolt holes neatly through the vinyl first with a scalpel (or a cutting compass - handy studio item!) so there's no risk of it snagging on the drill and chewing it up. (Loved your article, BTW.) Edited by - tony pashley on 17 Sep 2003 18:46:37 Link to comment Share on other sites More sharing options...
CharlesElliott Posted September 17, 2003 Share Posted September 17, 2003 I've just had another look at mine and the metal strip seems no more than 1mm wider than the metal 'hats' which you use when mounting the harnesses. To drill holes for these in the metal strip would almost definitely end up breaking it into more than one part. So in this case, I may follow the manual and remove it. I'm still not sure why it suggests drilling new holes for the poppers when the pre-drilled ones seem fine. Charles --- My Caterham Academy 2004 Diary Link to comment Share on other sites More sharing options...
Mr Locust Posted September 17, 2003 Share Posted September 17, 2003 I started the holes for the belts and folded the strip to extract it through the holes - no unstitching required. Then I cut it into lengths to stiffen between the bolt positions only 😬 Ian Green and Silver Roadsport 😬 Link to comment Share on other sites More sharing options...
CharlesElliott Posted September 17, 2003 Share Posted September 17, 2003 I might just follow you there Ian. Did you use the existing (6) drilled popper positions, or did you drill one halfway between the harness mountings each side? Charles --- My Caterham Academy 2004 Diary Link to comment Share on other sites More sharing options...
andy couchman Posted September 20, 2003 Author Share Posted September 20, 2003 Thanks Tony! When I initially built the car (88/89) I removed the ali (not steel as I put in the first post) strip and ran it without. It worked OK but air could get in between the poppers so I used velcro strips to keep everything roughly in place. Not perfect... I also used poppers on the frame as well as the cover so had a boot that opened from the front as well as from the back. On the recent rebuild (thanks for all the advice guys - v.helpful) I removed the strip, drilled it and then re-fitted it and sewed up the plastic again. What made me nervous was that the strip is only just wider than the bolt so careful drilling was required. All seems to look OK now and as the rebuild has no spare wheel I have reverted to 'proper' opening from the back only. The only downside is that you can't remove the boot cover when running a hood (yes, the car now has a hood - we must both be getting old!) Andy Q831FDD Link to comment Share on other sites More sharing options...
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