The following documents an approach recently used to install the door hardware and the door upholstery to an XK-150 roadster.
Also included is a list of typical fitting problems encountered during the process along with remedial action to complete the installation.
Installation of Door Hardware
1. Install sound deadening material.
2. Install door latch mechanism.
3. Install outside door handle. Fit the two rubber mounting pads and secure the handle with the special machine screws by accessing within the door cavity. Ensure that handle will unlock the door. Any needed adjustments can be made at the bolt and locking nut at the back of the plunger.
4. Install window channel.
5. Install regulator assembly. Raise window glass and frame assembly and secure it close at the end of the run. Insert the regulator assembly from the map compartment (at the bottom of the door) up into the door cavity. Position the window regulator assembly and loosely secure with one screw.
6. Connect window regulator assembly to channels of the window glass and frame assembly. Release the window glass and frame assembly and lower it down the channel with the leading edge tipped toward the front of the car. When close to the flange of the window channel assembly, secure the front roller of the window regulator assembly to the window glass and frame assembly and then secure the second roller to the rear channel. Maneuver the window glass and frame assembly now attached to get alignment to secure (with machine screws) the window regulator assembly to the door hardware mounting panel. (The door mounting hardware panel is the angled, inner-section of sheet metal in which the door latching mechanism and the window regulator assembly is mounted. This panel is finished by capping with a main door panel in its British vinyl.)
7. Install the three retaining brackets of the window channel. This would be the L-shaped bracket at center of door and brackets at each end of door.
8. Fit regulator limiting tab. This square plate, with its set screw, fits inside the track of the front bottom bracket of the window glass and frame assembly. Lower window so the chrome frame top is flush with the top of the door. Tighten set screw of regulator limiting tab.
9. Install exterior chrome armrest at the top of the door and the chrome finishing tab at its rear. Facing the door skin, place the leading edge of chrome over the top front of the door, when hooked move it toward the center of the door to slide the locking tab into the door. With the left hand, swing the chrome toward the rear of the door and sweep across the rear of the door while keeping the chrome in place with the right hand. Then, at the rear of the chrome carefully guide it over the end of the painted door into a position to install the chrome plated retaining screw (No. 4 x ½). Then, place the folded end of the "T rubber" under the chrome tab and secure with a similar chrome plated screw.
Installation of Upholstery
1. Install piping. Use the old piping as a guide. Note the original cuts which enable the piping to be shaped around the door. If the old piping is unavailable, duplicate the leading end as the factory by removing about 1 ½" of stitching to access the internal cord. Cut the cord, flatten the 1 ½" end and tuck inside the top of the door cavity between the window channel and the door hardware mounting panel starting at the hinge end of the door. Locate the topmost 1/8" pop rivet hole at the top of the door and start riveting the piping at this hole. Proceed counter-clockwise. Three (3) cuts are needed in the piping to make it easily form around the door. Starting at the hinge end, the first cut will be the removal of a triangular-shaped section of piping at the first angle after the top rivet. Cut only to the stitching. The second cut will be at the front corner of the door bottom. Cut about a 1" rectangle again only to the stitching. The third cut will be at the rear corner of the door bottom. This cut is the same as the preceding cut. Locate the remaining factory rivet holes, punch through the piping and rivet. The last step is to make a similar lead of at least an inch in length of piping at the last pop rivet as at the first. Remove the stitching, cut the internal cord, flatten, tuck inside the door cavity, and rivet.
2. Originally a plastic sheet was fitted over the door hardware mounting panel. Glue new plastic sheeting at the top leaving the remainder loose. Fitting of the various bolts and brackets which fasten to the mounting panel is adequate to secure rest of the plastic sheet.
3. Install map panel box. This should have been previously lined with moquette and British vinyl.
4. Attach the main door panel retaining assembly with four pop rivets to the door mounting hardware panel.
5. Glue the British vinyl of the map panel box to the main door panel retaining assembly. Fold the vinyl with a blunt-ended screwdriver by gently forcing it into the channel of the main door panel retaining assembly.
6. Install the map panel box cover. Use the original factory holes as a template for drilling two holes in the metal of each end of the map panel box cover. Position the cover and ensure that the beaded edge of the piping abuts snugly to the lower edge of the map panel box cover. Rivet one end and tension the panel as the other end is riveted. If not, the panel may flex and look unsightly.
7. Fit the top left casing assembly. Ensure that two locating tabs are positioned correctly as the assembly is slid toward the piping edge. Fasten with two No. 6 x ½ sheet metal screws.
8. Fit the top right casing assembly. Ensure that two locating tabs are positioned correctly as the assembly is slid toward the piping edge. Fasten with two No. 6 x ½ sheet metal screws.
9. Fit the top casing assembly at the top of the door. Lower the window to the bottom. Angle the assembly to hook over the edge of the door mounting hardware panel. Tap into position and ensure that each end fits snugly to the piping. Starting at the center, fasten with two No. 6 x ½ sheet metal screws. 4
10. Fit the main door panel assembly. Do a trial fit. Note the holes for the two retaining clips at the top of the assembly toward the latch end of the door. The clips must be fitted and aligned before permanent mounting. Begin the trial fit by placing the assembly in the channel of the map panel box, then pressing it toward the outside of the car, negotiating into the armrest threaded rods, the inside door pull, the window regulator stud, and finally to the door hardware mounting panel. Trim the perimeter to fit snugly between the previously placed casing assemblies. Also, carefully trim the vinyl around the inside door pull and mounting pins.
11. Fit the arm rest by sliding it on the threaded rods and securing by the special nuts. Tension loosely. After everything is installed, snugly tighten the nuts. Too tight will wrinkle the vinyl and cause an unsightly appearance.
12. Fit the inside door pull hardware. Position the small chrome plate and then add the cover on top and fit both with the special machine screws. Fit the door pull knob and secure with the small set screw.
13. Fit the window regulator handle housing over the window regulator stud, then fit the handle, press in, fit the locking pin, and release tension on the housing.
Typical fitting problems
1. Aluminum casing panels are formed out of shape. Use the original mounting holes as points of reference and bend the panels to attain fitment ease.
2. Premanufactured main panel may need "site trimming" to fit properly. Peel back the cover from the panel, cut accordingly, trial fit, and reapply adhesive to refit the cover.
3. Inner sheet metal of door (door hardware mounting panel) may be compressed at the top. This may not be apparent until the fitment attempt of the top casing assembly. One remedy is to enlarge the opening with a carefully placed and wrapped pry bar.
4. The armrest studs may be bent at the wrong angle. This is an easy fix by rebending and refitting the armrest until it easily slides up the threaded studs.
5. Screw hole for mounting exterior chrome armrest may be enlarged. This may be remedied by judiciously placing JB Weld, then drilling and tapping.
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