Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Broken front upper shock mount

Good work well done

Well done Richard.

That was quick Richard, good delivery from Uncle Melvyn too.

Many thanks. Will tackle the gearbox filler plug access next.

Good luck on the oil filler.

Thanks it will give me a chance to hone the dimensions I measured from underneath so will advise. A tentative 2mm hole first I think

Richard this is the hole saw drill I used to make the holes.
You remove all the saw blades apart from the one you want by unscrewing the flat head screw, but you can also reduce how far the drill sits above the sawblade by undoing the cross head screw and moving the drill bit..

So in theory you could set it so that the drill is short enough to pass through the ali but not so long as to hit the gearbox.

Let me know if you want to borrow it.

I used to have exactly that version John. It's disappeared in the annals of time though so bought a similar one today with multiple size cutters. Unfortunately unlike yours my arbor drill had no sliding adjustment. Given less than 15mm clearance behind the ally cover before contacting g/box filler plug, I had to grind nearly 10mm off the drill shank.

Unclipped leather gearbox cover fixings and gently peeled back cover which was very lightly glued down on my car. Using earlier measurements, drilled a 2mm hole then checked underneath to find protruding drill bit within a few millimetres. Compensated then used the new kit with 29mm cutter.





The square drive bit sticking out is the correct 5/16" hex key on the filler plug. 8mm is very close though. If you zoom in you can just see black lip of plug.

Updated dimensions for anyone interested in gaining access to g/box on 3.7 Roadster as follows:

Hole position 190mm forward of forward edge of bare crossmember (measured along floor at 90° to member). Then 85mm up from floor board. Latter is a little tricky to transfer to ally due to carpeted step in cover. I used calibrated try square and metal rule. Double check with small pilot hole first though as this is a Morgan

Will get around to making a cover once I find some ally sheet.

Richard. Are you sure that the damper is not arriving at the end of stoke before the springs arrive at full compression. If the damper does not have enough stroke it may be putting load on the bracket at full bump.

Please stop, I'm getting hole envy

BTW, Richard, could you add these to the original G Box hole thread that John started ? So it's easier to search