Body/chassis clearance

[Pete Boole]

So I don't have to wait 'till my body goes back on - can anyone remind me how much space there is between the body and the top of the chassis in the area of the handbrake lever? ISTR it's about 1/4" to 3/8". I want to fabricate a strengthening plate for that area to reduce flexing.

Thanks

Pete

[DavidOliver]

Pete, the Elite manual, Page 16 of Body Section refers to spacing of the body to chassis, indicating how not to stress the body to avoid door voids losing dimensions.
Personally I would use firm rubber thin spacers glued (finally) to the chassis in the area you mention after tailoring the body/chassis interface and allowing all fixing points to be a free fit, that is no gap between body and chassis except the rear fixing, adjusted as per the Elite Manual. Body and chassis flexion is different as they perform different functions when driving.

Dave the cog.

[AndyC]

I've not seen an Elite chassis, but would it not be possible to put the reinforcement plate inside, then attach it by puddle welds in holed drilled in the original metal?

[Pete Boole]

Pete, the Elite manual, Page 16 of Body Section refers to spacing of the body to chassis, indicating how not to stress the body to avoid door voids losing dimensions.
Personally I would use firm rubber thin spacers glued (finally) to the chassis in the area you mention after tailoring the body/chassis interface and allowing all fixing points to be a free fit, that is no gap between body and chassis except the rear fixing, adjusted as per the Elite Manual. Body and chassis flexion is different as they perform different functions when driving.

Dave the cog.

Thanks Dave - but - it's just the flexing of the handbrake attachment point on the chassis that I want to reduce. It's just too bendy for my liking!

Pete

[Pete Boole]

I've not seen an Elite chassis, but would it not be possible to put the reinforcement plate inside, then attach it by puddle welds in holed drilled in the original metal?

Thanks Andy. The Elite chassis is fundamentally similar to the Excel in that area (although I can't quite remember exactly what the Excel handbrake fittings are like ). I'd thought about putting the reinforcing inside the chassis, but the welded-on nuts for the handbrake fixing make it slightly more difficult. My plan is to put some 1/4" aluminium plate over the whole area (5" x 8" with slot for handbrake) and fixed with countersunk screws to the top of the chassis. On the Elite the handbrake fitting brackets are raised on little spacers anyway, so the plate would raise the handbrake lever to the correct height and reduce the flexing at the same time. I just can't remember how much space there is between the top of the chassis and the underside of the fibreglass (although I'm sure it is at least 1/4"). I'm just on with the handbrake cable at the moment and want to finish it - too impatient to wait 'till I test-fit the body to assess the gap!!

Pete