Two things left to do: bolt the bonnet on and get it to release correctly and finish and install the screen.

The bonnet first, Vic and I spent a happy half hour bolting the bonnet on, it fits in the aperture quiet well although one side is a little higher than I would like but that will be another task for the winter.  I mounted the bonnet catch and aligned it using the masking tape and paint technique learnt on the AH Experience website.

Then this happened:

Very happy and onto the final task, the screen.

The screen glass was nicer to fit than the second hand glass I used last week, it was thinner and so was the rubber that came from Moss.  I had to bend the channels a tad to get them to line up and it was surprisingly easy to do that by putting them over my knee and pushing.  It went together well.

With Vic's help it went into the pillars, not effortlessly but it was forced either.  I am conscious that I will not be inclined to try and lay the screen flat though and this is crazy as it is one of the features that made me fall in love with the car in the first place. So having stalled the screen and given the car a wash there was nothing stopping me driving it.  

After eleven years I am now going to do something that felt very far away for the majority of that time.

I was beyond nervous and completely over excited.  I took it out and went round the block twice before venturing a little further afield and eventually stopped at my mother in-law's house for a photo and a break.  It was as I could have expected with the benefit of hindsight; an old car in need of some setting up.  The brakes were good, as was the engine and the drive train.  The steering was shocking though.  It also got a little too hot but it was a very hot day for London and I guess the timing needs refining.

Even as I type now I can't quite comprehend that the journey has come to an end.  Eleven years, just like that.  For sure I have many more hours to spend on the car sorting the engine and steering for starters then the tonneau, roof, side screens, carpet, trim etc, etc. but it is different now, it is a car.

A friend called round as I was recovering and we went for another lap of the local area and he pointed out that people were shouting at us.  I realised that people were actually doing that, crazy.  I'm going to enjoy this car.

Boy, does it look good.

Started the day with three jobs between me and a first ever road trip in the Healey: Grille, windscreen & bonnet.

The grille was first.  I trial fitted it and thought that the inner section was still not as good as it could be so I made some adjustments and then bolted it on.

Very pleased with that so onto the screen.  I laid out a sheet in the garden to remove the broken used one from the frame and set about pulling it apart.  It was very hard to get the U channels off the glass and I am already glad that the new glass appears to be thinner.  I did get it off though and disposed of the old glass.  I had marked the frame with what I thought would be the required adjustments before I took it apart.

I checked all of the brackets and replaced two of them with brackets from the new set bought from Moss.  These appeared to be identical to the original set supplied by AH4H.  

I was unable to file the corners down, it turns out that chromed brass is incredibly hard.  This meant that I had to use the bench grinder, that was quite a scary moment I can tell you.  As I put the frame back together and tested it in the mountings on the car I became more and more conscious that these were not in the correct position.  I previously wrote that this is on original metal so should be ok but I look at them now and see that the shroud is quite pronounced on the passenger side, the same side that the screen is too high on.  Also, I am now more convinced that the angle of the bracket is out.  I bite the bullet and remove it.  Thinking back to my dad's day I remember him hitting a hammer on a panel to get an impact but reduce damage so that is what I did.  I took a panel beaters hammer and put it on the shroud where the mounting was sitting on and shacked it with a club hammer and it worked.  Remarkably the panel dropped down a few millimetres and all of the metal around it stayed undamaged.  This enabled the mounting bracket to sit on the car a few millimetres lower and once re-installed with a packing washers at the top all seemed much better.

I sat the glass in the frame and placed it in the car and it all fitted nicely.  I only needed to fit the rubber now and I was in business but that would be tomorrows task.

 

I finished the tunnel on the understanding to myself that I would research it in greater detail before I carpet the car.  You see the tunnel doesn't sit cleanly on the chassis and upon research I realise that it should sit on the underlay.  This strikes me as odd because that will enable water ingress.

Vic trying it for size.

I then stuck the boot badge on.Next up was painting the battery cover.  I decided I could face the agro with it being ICE blue so I painted it black.  Hell, it'll be covered in carpet in no time at all.  I also made the straps for the cover out of leftover leather from from the seats.

Today I collected the windscreen from Moss London, I always love going into a classic car shop and this didn't disappoint.  Now I didn't desperately need a dashboard handle but I wanted one; what can I say?

When I returned I started on installing the tunnel.

I started to fit the main tunnel section when I realised that I hadn't yet made the inspection panel, this was very enjoyable to do. 

When it got to a sensible hour I grabbed a beer and sat and gawped at the car.  I am feeling very lucky right about now.

Today is Wednesday 5th August 2020 and I am hoping to take the car to the Ace Cafe classic car night next Thursday, the 11th.  This is possibly hampered by the weather forecast of rain and as I won't have windscreen wipers installed this is definitely a major consideration.

Apart from that, these are the tasks I have left to do:

Install the bonnet

Replace the windscreen glass

Fit the grille

Fit the wiper mechanism 

Install the tunnel cover

Paint and install the battery cover

Install the fire extinguisher 

I am hoping that my lovely wife will have got me some wiper blades for my birthday which is on the day after the Ace Cafe night so I could ask her for my present a tad early.

Other than that I am conscious that I have two very tricky tasks ahead of me.  The windscreen is a real worry as the glass I have now installed has cracked multiple times and it must be it is out of line with the mounting brackets.  I had initially thought that it was the screen frame that was the problem and so I have ordered another set of corner brackets along with the glass from Moss which I am collecting this morning. I now think that the mounting brackets themselves might be out and this worries me, a lot.  I had not worried about this before as these brackets mount to the front bulkhead and that is one of the few structural pieces to be carried over from the original chassis.  But thinking of the fitting of the screen I am concerned that the bars that slide into the mounts from the windscreen pillars would not line up that well so I am concerned that the pillars may be out of line and changing that is going to be a big job.

I'm also extremely negative about the bonnet closing mechanism.  I know that the bonnet fits the car as I have previously installed it but I have not installed it with the bonnet catch mechanism.  What is the chance that this will line up?  based on every stage that I have got to so far in this rebuild I am inclined to think that this is somewhere around zero.  I have nightmares when thinking of the bonnet closing and not coming open again, it is not easy to get to.  Oh well, I shouldn't be worried about what might not happen.

The rest of the list should be ok to do.  Then I just need to drive the car, gulp.  It is now road legal with tax, MOT exemption, insurance and breakdown cover which is good. 

Going to be a week to remember.

I snatched a few hours in the garage today.  I had retrieved the bonnet from its long term storage yesterday but not yet fitted it so I plonked it in the hole it is supposed to fill just to keep it safe and was rather struck by how much of a car it now looked.

I spent a long while working out where I could put the fire extinguisher and ended up thinking that it is probably best in front of the passenger.  Will consult with chief passenger before I start drilling.

The main business of the day was to raise the steering wheel.  This was not simple.  I only had to remove one bolt on the bracket that clamps the wheel and slide this along the column one place in the line of holes and replace the bolt.  However, it was impossible to see this area and so the job was done chiefly by feel.  Also, I had used the holes in the main support bracket from the front bulkhead to the dashboard for earthing the loom so this needed to be removed.  The plates that bolt to the air box on the bulkhead also needed removing and replacing which required drilling, a task that was now tricky because the area was difficult to get to.  All in all, a very fiddly few hours for a difference of about 1cm in height for the wheel.

I could move the column up a little further but this would require some modification to the dashboard and that would be a major job so I will live with it for now and then decide on it as a future winter project later on.

Door: sorted.  Really pleased.  They both open and shut well, the door gaps are good, the safety latches work and the internal straps are in.  Took a whole day but it was a very successful day.

Working from the rear to the front I decided to fit the boot next.  I was slightly amused to realise that I couldn't find the gaskets for the hinges despite looking everywhere.  I hardly have any parts left now so haven't experienced this type of thing for a while.  In the end I made a set out of gasket material.  They worked but the boot doesn't sit at the correct height on the cockpit edge, something that I may look at in time.  When I bought the hinges the previous owner said that he didn't think they were well made and wasn't sure of their alignment; for now they'll do.

The boot handle didn't fit at all which was frustrating because I had to drill and file out the holes, this is the type of activity that I would have preferred to have tackled prior to the boot lid being painted, oh well.  Once done I scoured the internet for pictures of the rear of bumper-less cars to see what the common height for numberplate light is before drilling that out and fitting it.  Then the numberplate.  It being located so low on the rear made it tricky to align and I am convinced that I have it on wonky, again this is something I may look at later on if it troubles me.  

I have just one job left to do on the rear and that is to fit the badge on the boot.  It has three studs that should fit into holes on the boot but I have none.  Now I could take an educated guess at where they should be and then drill them but I am a little wary of doing so.  I decided to order some double sided tape and use that with the badge as that way I can move it around until I find the place that it sits best without worry for putting holes in the wrong position.

The rear looks fabulous.

I looked at the door next.  I have two jobs, fit the cable used for opening them from the inside and align them so that they open and shut correctly.  My only remaining original door is stored at my Mother In-Law's home and I went to look at it to see where the cable is mounted.  I'm a little disturbed that the return on the inside of the door needs to be cut away as the doors are aluminium and I suspect this will adversely affect their structural strength.  

I had removed the rust on the cable ends last week and painted them so all I needed to do was cover them.  I had enough off-cuts of leather from the seats which I decided to use as it felt nicest but does mean that I will need to make the cover is several sections.  I glued the leather to the wire initially and then stitched it.  These look fit for purpose.