Side Repeaters

I had been putting off the side repeaters as I couldn't decide which ones to fit until seeing some LED ones on the GD stand at Stoneleigh. They come with a black rubber grommet and optional chrome surround and I managed to pick them up at the show from CBS.

Fitting these is very straightforward once you've decided where you want them. Some people place them towards the rear above the louvres but I chose to put mine further forward.

I placed 25mm wide masking tape along the top and forward edges of the louvre opening, then another strip above and one behind. Where the tapes overlap creates a diamond shape above and inline with the forward edge of the opening.

Drawing a cross to join the opposing corners of this diamond gave me a centre point to drill a 20mm hole. Once the edges are cleaning up the side repeater just pushes in. I've order some two pin Econoseal plugs which I'll install later.

Repeat for the other side, all in about 20 mins work.

Taped up and centre point marked

Side repeater fitted

No More Bling

I never really wanted a Cobra with loads of shiny Chrome as I'm trying to build a modern alternative, but didn't think there was any other option for certain things such as the windscreen so just settled for it.

After recent discussions with fellow builders, I have decided I am going to go 'bling free' after all. The chrome/shiny bits I already have are:
- Windscreen frame and stanchions
- Fuel filler cap
- Headlight surrounds
- Wiper spindle ferrules
- Wiper arms and blades

The wiper arms and blades haven't been fitted so I will see if I can return them to GD and I'll buy black ones, I think Classic Mini ones fit.

I have made enquiries with a few local powder coaters and the consensus it that Chrome can be coated after being shot blasted to ensure good adhesion, and cheaper than I was expecting too.

I now needed to remove bits from the car, the headlight surround and wiper spindle ferrules just unbolt and the Aston filler cap needs a couple of roll pins knocking out but the tricky bit was the windscreen.

The powder coating process involves oven baking which isn't good for the rubber seals which meant the glass had to be removed and after speaking with Brasscraft (they make all the UK Cobra screens) I was assured it was possible.

The frame is made of two sections, the lower bit that sits across the scuttle and the rest. These are held together by 2 flat head screws at the bottom of each side. A sharp flat object needs to be run around between the seals and the glass, I used a 6" steel ruler. I then used a flat head screwdriver to prise the lower corners apart, I could then gradually ease the two sections apart.

The top frame is more difficult as it wraps around 3 side so there is more friction in the seals, I had to resort to a nylon faced mallet here! Whilst holding the glass, I lightly tapped the corner of the frame outwards each side, then upwards from the bottom.

This process was repeated gradually each side until I could pull the frame off the glass, thankfully with everything still in one piece. Now the seals can be removed for reuse when it all goes back together.

Two roll pins for the hinge and catch removed with a hammer and punch

Glass removing tools! 

This shows the two screw holes at the lower edge on each side. I'd already removed the lower frame before I remembered to take pictures. 

Prising the seal off the glass, a Stanley blade would probably have been better in hindsight. 

Two parts of the frame ready for the powder coaters 

Lights

Now that the light plinths were polished I couldn't help but bolt some bits on the outside of the car.

This was a nice and simply job so took less than an hour to install the six small lights (2 x front indicators, 2 x rear indicators and 2 x rear stop/tail), the headlights haven't turned up yet so will be fitted later. I want to keep the car looking clean and simple on the outside so I bought smoked lens LED landrover defender lamps rather than the classic lucas style coloured ones.

The centres were predrilled from GD which I double checked were centred then marked the centre lines vertically and horizontally. The holes were then opened uo to 20mm to allow the plugs to fit through. I then positioned the lights so there was 10mm to the edge of the plinth around the edge then marked the mounting holes with a drill bit.

These were pilot drilled for the self tapper screws, these will be replaced with M4 stainless button heads and nyloc nuts when the post arrives. They will be wired uo when the loom goes in.

Centre holes predrilled from GD

Horizontal & vertical centre lines marked and holes opened up 

Close up of rear lights

Rear lights fitted 

Front side lights fitted, headlights in the post.