Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Trads - High level brake light with Luggage

Another one reposted!!! Phew.

Hope that helps Arthur!

Great "How To" as usual.
Who made the cover, I think its the same Samsonite case I use.

The cover came with the case from Ledgerwoods. It was the standard Morgan set at the time including the boot bag.

So it was 13th February 2010 that I set about a high level brake light to be used with luggage. The unit described above has lasted well, but after unpacking the luggage, it either has to be folded forward onto the rack, or unplugged and put inside the Morgan.

I've recently been thinking this over, to get a semi permanent fix, which can stay on the luggage rack. The only viable place is the uppermost rack tube, which isn't really high enough, but all things considered isn't a bad compromise.

I had one piece of stainless steel left over which was the right shape, to use as backing. I began by making a fold down the length, Stainless doesn't crease-fold, it makes a gentle curve, which was ideal. From this I used my metal shears, which handled it well, and then I filed the edge, and finished off with abrasive paper. For the holes I used my best drills, and they cut through easily.

I was short of m5 bolts, so used m6, which are oversize really, and I had to file the heads down by 50% to get a fit.

The unit came from E-Bay. I used neoprene edging to tidy it up, but if I make another, I don't think it will be necessary. This is the "prototype"!!





I've added neoprene to the back for grip, and cut a badge bar bracket in half to make these two brackets, also lined with neoprene for grip.











I can attach this, and leave it in place for the duration of a touring holiday.

Dave that's a work of art, and chance you could PM me with the details as I have scrolled through 5 pages and cant find a list of parts?

Thanks Colin, I'll be in touch!

So I made a start on number two, taking all the lessons on board from my prototype.

It's quite amusing that what I assumed to be a sheet of aluminium propped up on the garage wall turned out to be brushed stainless steel. I found that out when I cut it, because stainless cuts very differently to aluminium!

Anyway, a few pictures will show the outcome. m5 instead of m6 fasteners, and dome headed allen setscrews. All that's left to do really is to add the neoprene backing and set the screw adjustment for a good grip on the luggage rack. It's way better than mine, but that's what prototypes are like....a bit rough around the edges.

Here's the stainless steel backing plate:





Test fitting the badge bar brackets:



The light fitted with neoprene gasket:





I must be getting better at this. In the early days I regularly messed up stainless steel, but now I can make just one without messing up!!

Interesting work as always Dave.

Dave did I mention I have a wonderful metal bending machine I used to make some A post pillars to secure my hard top.

Available to borrow...

Superb!