GTM Libra - Main build manual

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BOOT, BOOTLOCK AND HINGES The Libra has a good size boot located at the back of the car above the exhaust system. This boot has an external lid to allow easy access. The boot is lockable from the outside and has its own hinging and support stay mechanism. The boot is large enough to accept a full size set of golf clubs. Boot, Boot lock and Hinge assembly Refer to drawing No 20. The boot hinge mountings TO643 are mounted to the rear panel TO102 on the small rectangular faces in the rear quarters of the rear screen. The rear screen needs to be removed before the boot can be fitted. From the inside of the rear screen aperture mark the four Ø6mm clearance slots as indicated on the drawing. Use the boot hinge mounting bike back plate TO644 as an accurate guide to the centre positions. The slots will be covered by this component when the boot is finally assembled. Take the boot lid TO103 and turn it upside down on some suitable clean and protective surface. Mark the position of the four boot hinge location holes on the outside surface of the inner strengthening frames as shown on the diagram. Use boot hinge backing plate TO641 as an accurate guide to the centre position and slot the holes Ø6mm clearance to give yourself sufficient room to adjust the boot panel when assembled. Mount the two boot hinges to the strengthening frame using four Ø6mm socket cap screws and washers with the backing plates on the inside of the box. By loosening the screws the boot hinges should slide for adjustment against the outside face of the strengthening boxes. Referring to the diagram showing the view from within the boot mount the two boot hinge mountings TO643 to the boot hinges TO640 using the boot hinge pivot pins TO642. Note that the boot hinge mountings when attached to the rear panel make sure the pivot pins are located as close as possible to the top surface of the rear panel. The pivot pins require a small amount of grease to make them work satisfactorily. Fit the boot panel to the car. Holding the boot panel open, position the boot hinge mounting with one hand and attach the boot hinge mounting to the rear panel using the boot hinge mounting backing plate and four Ø6 x 25mm long socket cap screws and washers. You may require the assistance of another person to hold the boot open while undertaking this operation. The boot can now be opened and closed. It can also be adjusted to give an equal gap around the boot aperture and to line up the panels with the outside surfaces. Take your time doing this operation, as it is extremely important for the use of the car that the panel opens and closes without difficulty. © GTM CARS LTD. 1.3
Mount the boot stay slider TO645 to the vertical surface of the rear boot panel inside the boot in the position indicated on the view from within the boot. Use the slider as a template to locate the hole positions and drill Ø6mm clearance holes. Mount the slider to the boot panel using two 20 x Ø6mm socket cap screws, washers and Nyloc nuts. Fit the boot stay rod TO646 to the hole in the bottom corner of the boot hinge and to the boot stay slider using the spring fixings TO647. Do not grease this slider as in operation it is necessary to touch the slider to lock the boot in the open position. By lifting the boot slightly the slider should unlock automatically. Adjust the height of the boot stay slider to obtain the maximum boot lid opening without the boot lid top corners hitting the rear Perspex screen. Mount the boot latch TO652 to the outside surface of the boot panel under the position for the number plate in the position shown on the diagram. Use the latch to determine the position of the holes required. Drill or hole saw Ø20mm hole in the corner of the rebate in the boot lid for the boot latch as shown on the diagram. This is to allow the operating rod to pass through it towards the position. Mark the centre of the key position on the left-hand side on the boot lid within the recess on the mouldings. Hole saw an Ø25mm hole. File the two anti rotation notches in this hole. Due to the increased thickness of the glass fibre body compared to the steel body, the notches in the K Series Rover Metro lock have to be wider to enable the retaining clip to work satisfactorily. Mount the lock in a vice and carefully saw the door lock barrel to increase the width of the notches to approximately 4-5 mm. The lock can now be assembled to the boot using the standard Rover Metro retaining spring. Mount the boot latch to the boot lid using two Ø6 x 20mm long socket cap screws, 4 large washers and 2 Nyloc nuts. Take approximately 200mm of the door rod wire TO523 and form a 10mm long right angle bit at one end. Feed the other end of the wire through the boot latch and through the hole in the moulding, towards the lock on the left-hand side of the boot. With the boot lock operating lever in the vertical position, mark the position on the wire and cut and form a right angle bend. Connect the rod to the lock and using the boot striker manually into the boot latch, check that the latch and team mechanism operates correctly and freely. Mount the boot striker TO653 to the rear panel as shown on the diagram using two Ø6 x 20mm long socket caps, screws, washers and Nyloc nuts. © GTM CARS LTD. 1.4
Page 2 and 3: SECTION TITLE 1. Bonnet and Boot fi
Page 4 and 5: BEAM END COVERS Beam end covers are
Page 8 and 9: Fit the boot rubber seal TO655 to t
Page 10 and 11: CARPETS The GTM Libra comes with a
Page 12 and 13: DASHBOARD TOP AND DEMISTER VENTS Th
Page 14 and 15: SEATS AND RUNNERS The Libra utilise
Page 16 and 17: SEPARATE INSTRUMENT OPTION In stand
Page 18 and 19: connectors. By wiring the fan switc
Page 20 and 21: half of the car. In the standard ki
Page 22 and 23: DOORS The Libra uses two glass fibr
Page 24 and 25: to enable the retaining clip to wor
Page 26 and 27: The arm that normally projects into
Page 28 and 29: ROOF PANEL A removable roof panel i
Page 30 and 31: ENGINE COVER MOULDING The engine co
Page 32 and 33: may be necessary to strain the fram
Page 34 and 35: FRONT AND REAR SUSPENSION FRONT SUS
Page 36 and 37: T0208 - FRONT BOTTOM SWIVEL. T0209
Page 38 and 39: Hold the completed bottom wishbone
Page 40 and 41: 2 x T0311 Rear suspension arm track
Page 42 and 43: Locate the two shock absorber brack
Page 44 and 45: Radiator mould, radiator & pipe wor
Page 46 and 47: attached to the heater unit using t
Page 48 and 49: The Ø6mm breather pipe is taken up
Page 50 and 51: assembly on the right hand side. A
Page 52 and 53: All other cables through the tunnel
Page 54 and 55: HEADLIGHT COVERS………………
Page 56 and 57:
saw, opening up a hole just big eno
Page 58 and 59:
FRONT & REAR SCREEN AND WIPERS SCRE
Page 60 and 61:
and tinted and the rear screen is t
Page 62 and 63:
ELECTRONICS & WIRING WIRING……
Page 64 and 65:
Unfortunately the Rover 25 engine b
Page 66 and 67:
the rear panel of the car to be rem
Page 68 and 69:
through the wire to the handbrake w
Page 70 and 71:
to the same bolt on the gearbox tha
Page 72 and 73:
At the rear take the longest brake
Page 74 and 75:
cables and handbrake lever are used
Page 76 and 77:
PEDAL BOX AND MASTER CYLINDER The L
Page 78 and 79:
throttle runs freely and make sure
Page 80 and 81:
EXHAUST The exhaust system on the L
Page 82 and 83:
SETTING UP THE CAR FOR THE ROAD The
Page 84 and 85:
the car. Once you have set these bo
Page 86 and 87:
Build Notes © GTM CARS LTD. 13.2
Page 88 and 89:
Build Notes © GTM CARS LTD. 13.4
Page 90:
Fitting Guide NEW SUSPENSION (Issue
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GTM Libra - Main build manual

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