Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Dave's How To: Workshop Notes 3 continuing.

I haven't been idle since my last instalment. So here's an update on work in hand.

First the front UJ grease nipple. Not entirely clear from the photo but a standard gun won't fit because the UJ yoke gets in the way. It's a matter of one or two mm. When I get a needle dispenser I'll post a picture.



This is my Centenary badge. It's badly pitted. I tried a vinegar bath and it did help a bit, but except for the centre rectangle, which appears to be proper enamel, the rest of the black is paint which shells off. At the moment I've removed it all, after trying to lacquer the badge as a preserver. It didn't work. Disappointing quality.



This next photo is looking down at the inner wing. I've grommeted nearly all the holes in both inner wings and there are plenty. This one is an elongated slot which is used to provide clearance for the steering column, but is on both sides. Anyway, having considered leaving it open, I decided to seal it with a Reflect-a-Cool adhesive patch.



And while the Reflect-a-Cool was out, I made up a sausage for the intake tract.



I've been pressing on with my undertray. It needs to be in two parts, and the easiest piece to do is that which goes between the crosstube and the sump. I'm now confident enough to use 1.5mm aluminium, bent in my wood and G clamp metal bender:



Having begun with a cardboard template - the panel I fitted to Bumble slotted over the lower chassis horizontal, but this time I've fitted it underneath, with a neoprene gasket, and secured using the towing eye bracket fixings, and the two holes on the opposite side. The angled flanges at either end make this strong.





This is the completed item:



This is the gap:



And this is fitted:





More to follow shortly.....................

The section from the cross tube forward takes a lot more effort, and I've been working on this for a few days on and off.
I removed the over-riders and front number plate box and took the opportunity to improve the paint on the back of the over-riders. This is VW Reflex Silver.



After cutting the aluminium sheet to an approximate size, the fun starts. First the front bend - done over my jack handle.





Use decent snips............





This is how I got a match each side. After cutting as much as possible it's painstaking filing.







Now came the tricky bit. On both my previous Morgans the over-rider brackets are fitted with the horizontal flanges facing each other. These flanges have four holes and these can be used to secure the front valance. But on this car the brackets are the other way round. So I had a choice of either changing them round, or making my own brackets.

So here is my starting point. Two brackets fabricated together and then cut in half. The front one is on the vice, the rear is over the screwdriver.



This is how they fit, using existing holes.







Now painted black and fitted:





After test fitting and adjusting:



After etch primer and grey primer. The hairdryer is to warm things up. This is today and it's a bit chilly and damp.



First coat of yellow. This is a base coat and is FIAT yellow. Now I must be patient and let this harden off for a few days before flatting down, and applying more yellow and lacquer. Painting is my least comfortable activity - I'm not patient enough!!!



Pictures of final fitting will follow in a few days, depending on how the paint goes on.

Another great job Dave - thanks for all the detail.

Only one thing...you make me feel lazy about my car!!!

Look at your inner wings Perry. They have a lot of holes. Most are hole punch size, but some are two pound coin size. And also in the chassis. I prefer to seal them up, just to stop splash back of road dirt.

Thanks Dave good stuff. My centenary badge is equally worn & now off the car.

Dave, my centenary badge is also looking gfotty. I have taken it off to clean up but it looks like it will not be brilliant. Pitting, poor enamel etc.

Cheap tat alas. Not sure how to resurrect mine.

Ditto, They really were truly shabby bits of kit.

I really regret putting mine on the car but if you don't then what's the point?
The threaded studs are ghastly now.

Interesting as ever Dave.