More fittings

Thurs.15.05.08. The radiator fan and the steering column has been fitted. The brackets that had been fabricated earlier in the project have proved to be more than adequate to support the entire assembly. The 2mm steel that was used had been designed in such a way that when the radiator was attached it would form the third element of the engineering triangle. In isolation the brackets have always seemed too lightweight and flimsy but combined with the other components they are remarkably robust. The steering column has three fixing points. Located between the fixed scuttle top bracket, the original steering rack but  there is also a midpoint ‘bearing’ bolted then ‘glassed’ into the bulkhead to ensure the stability, response and smooth operation of the complete mechanism.       

I have been bold enough to attempt the alteration on the dashboard to improve the presentation of the switch back plate. It has been necessary to cut the full plate into two pieces: to remain as one piece would have meant that there would not be sufficient tolerances left in the timber for safety. The upper three way light switch plate does not require to be recessed as there is ample depth for the switch to operate efficiently. The lower plate contains two toggle switches, the cigar lighter, ignition and starter button. Cutting a 5mm rebate to accommodate the plate will improve their access and function. The original steel plate was cut using a jig saw; the edges being later ground and filed smoothly. The recess in the dash was accomplished using the rotary cutter followed by a wood chisel to remove the excess wood. The task has been successful. All that remains is the ‘infamous’ dry run to ensure that everything will operate properly.

Fri.16.05.08. Once the leather had been glued to the switch plate it was necessary to shave 1mm from the lower edge to accommodate the depth of the leather. The plate now sits tightly into the recess but will require very strong adhesive to secure as a permanent fixture. The upper plate has been fastened to the dash by means of four 6mm screws that penetrate the hardwood by only 1mm thus avoiding cracking the lacquer on the face side but should also hold the plate securely.

But, the major problem that has been exposed, is the fixing of the overdrive switch. A rectangular section had been removed from the back of the dash to accommodate the mechanism this would allow the switch to protrude sufficiently to be operated. Unfortunately, there is not enough clearance to fasten the locking nut to permanently fix the unit to the dash. The solution, at this moment in time, is not obvious: research will be required. The joy of negotiating the pitfalls of the previous exercise has been diminished in the light of this new problem; but tomorrow is another day.