Talk Morgan Forums Morgan Sports Cars Classic Morgans (pre-CX) Refitting order of frame and panels?

After successfully replacing all rotten wooden parts I did a trial fit of the bulkhead and frame on the restored chassis. One thing I did not notice before was that the bulkhead is slightly warped. While there is a tight fit on the right side of the car, there is a bit of a gap on the left side (as can be seen on the picture below).

When I use some clamps to force it together - the scuttle bar top of the frame moves slightly for- and upward - which in turn lifts the door a little, increasing the gap to the lower part of the frame.

What is the best/recommend approach for refitting? Should I first put all panels back onto the frame and then screw down the bulkhead to the frame?
Or is it better to first attach the bulkhead and frame and then refit all panels?

Looking forward to your inputs.
Regards
Tim

Bulkhead on first with only the 1/4" fasteners along the front (toeboard) done up.

Then fit the body frame, make sure its bedded in on what ever you are putting between chassis and bodyframe

Then when the body frame to bulkhead join is as good as it can be and allowing for a bit of sealant between the bulkhead and bodyframe, fit the fasteners on the side of the bulkhead

Then fit the inner wings

Arwyn

Thank you Arwyn - good explanation. Makes perfect sense when I read it. Not sure why I did not immediately think about removing the fasteners on the side of the bulkhead.

What a terrific job.I think we would all like to see as many pictures as possible.I m rebuilding a Morgan Plus 8 but not as advanced as this.I will endeavour to send images.

I do have a problem at the moment with half shaft replacement.
I took both half shafts out along with hubs and brake assemblies.

However i cant get the off side half shaft home.
Its a BTR unit any suggestions?

Francis, try swapping them around, the splined end gets slightly worn in the direction of travel therefore always fit nearside to nearside and offside to offside.

David Byrne

The shafts are different lengths on a BTR axle
The shorter one goes in the near side

Francis’ car also has non standard axle shafts, because it is fitted with an early iteration of the floating axle kit