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smooth operation of the glass within the rubber channel.<br />
Remove the window glass from the door inner frame and place aside. Mount<br />
the K Series Metro window regulator to the door inner frame in the position as<br />
shown on the assembly drawing using two Ø6 x 15mm long socket cap<br />
screws and washers.<br />
Mount the short (120mm long) channel to the inner doorframe in the position<br />
shown on the assembly drawing using the standard Rover Metro 5mm nuts.<br />
Fit the door regulator top stop T0521 to the door regulator using a Ø6 x 18mm<br />
long socket cap head screw washer and Nyloc nut.<br />
Fit a winding handle to the regulator and check that the regulator winds up<br />
and down satisfactory without jamming.<br />
Wind the regulator to a position so that the operating legs are just below the<br />
bottom arm of the inner door frame and remove the regulator by unscrewing<br />
its Ø6mm retaining bolt.<br />
Slide the door glass into the inner door frame to a position where the channel<br />
approximates to the position of the operating arms prior to removing the<br />
regulator. Now slide the operating arms of the regulator on to the bottom<br />
channel attached to the glass from the rear end of the door at the same time<br />
ensuring that the small wheel of the regulator arm fits into the small channel<br />
already attached to the door inner frame. Position the regulator so that the<br />
two Ø6mm bolts can be replaced and mount the regulator.<br />
The window glass should now wind up and down the door in the frame without<br />
jamming.<br />
Do not at this stage attempt to adjust the position of the small 120mm channel<br />
or the position of the eccentric top stop. This will be adjusted once the frame<br />
is assembled into the door.<br />
Locks and Hinges Assembly<br />
Put aside the two inner frame regulators and glass and assemble the locks<br />
and hinges into the glass fibre door shells.<br />
Using the full scale template included in the assembly <strong>manual</strong> mark the inside<br />
recessed shut face of the door where the Rover Metro latch will fit. Using the<br />
other template follow on from the previously marked hole for the striker onto<br />
the inside face of the door using the template provided in the assembly<br />
<strong>manual</strong>. Spot and drill the three Ø6mm clearance holes in the door face.<br />
Using a jigsaw or by chain drilling, cut out the aperture for the striker. Using<br />
the Rover Metro door latch as a guide clean up the hole to allow the latch to fit<br />
snugly. Do this work carefully, as it will be seen on the completed car.<br />
Radius the edges to obtain a neat appearance. The door latch can now be<br />
mounted to the door shell using three Ø6mm button socket screws 20mm<br />
long with washers.<br />
Cut a Ø25mm hole in the centre of the recess for the external door key. This<br />
hole can either be cut with a hole saw or by chain drilling and filing. File the<br />
two anti rotation notches in this hole.<br />
Due to the increased thickness of the glass fibre body compared to a steel<br />
body shell the notches in the K Series Rover Metro door lock have to be wider<br />
© <strong>GTM</strong> CARS LTD. 3.2
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