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911 Door Mirrors as they arrived from Naz- I only have 3 out of 4 of the main pieces. Naz doesn't have a drivers side base plate made up- guess I'll have to wait a little longer for that one.
Viewed: 341 times.
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| 912 Drivers Door Mirror- On closer inspection of the mirror I noticed it was not the same thickness all the way around.
Viewed: 327 times.
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| 913 Drivers Door Mirror - Highlighting the inconsistancy of the moulding
Viewed: 293 times.
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| 917 Drivers Door Mirror- Its so thin in 1 place that there is a hole.
Viewed: 304 times.
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| 918 Drivers Door Mirror- Its also Cracked.- MMMMMM. I rang Naz and told him I wasn't happy and he agreed to replace it.- when new ones are made....guess I'll wait a little longer...
Viewed: 332 times.
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1098 Mirror Sanded and filled- Fortunately the Passenger Door Mirror was better so I set to work prepping it.
Viewed: 294 times.
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| 1109 Bumperfiller- I found this, together with plastic primer at Halfords. Ideal for the plastic injection molded mirror. The plastic primer is needed as normal primer will not adhere to the surface.
Viewed: 302 times.
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| 01099 Mirror being filled for imperfections- Once sanded I used the bumperfiller to fill all the little areas and 'bubble holes' in the moulding.
Viewed: 288 times.
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| 01101 Mirror Internal -Filling was also needed on the internal of the mirror. Though much better than the Drivers side, the mirror did need building up on the top leading edge in particular to make the edge the same all the way round.
Viewed: 312 times.
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| 01112 Hollowed mirror stems detail- Once the main part of the mirror was sanded I dremelled out the stems to hollow them enough to allow the base plate to fit, and drilled the holes through to take the springs. I took out quite alot of material and found a problem... The stems didn't quite match up with the baseplate and so the fit would be bad. I had no option but to add bumperfill material to the stems and reposition them slightly. Once done I inserted the gaskets and squeezed in some bumper filler to give the above profile. As they are rubber the gaskets just peeled out afterword leaving a nice profile.
Viewed: 311 times.
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01116 Mirror Stem Hollows Before and After- Here you can see just how much work is needed on the stems...
Viewed: 338 times.
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| 01104 Mirror Internal springs and tubes. In order to make sure I had the correct positioning for the stems to baseplate I fixed the mirror together temporarily with the tubes and springs
Viewed: 309 times.
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| 01111 Spring -tube attachment closeup. The springs have 2 ends, One with a close loop and one with a slightly opened one. You need to open this end up a little more and then clip it over the tube inside the mirror.
Viewed: 279 times.
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| 01108 Mirror-springpuller- gaskets and internals. I needed to make up temporary gaskets from some rubber so that when sanding and filling over the stems I did not ruin them. You can see one next to the real gasket in the lower half of the picture. Also shown in my 'springpuller'. When inserted, there is no way of pulling the spring through the mirror under tension so I degigned a hook and handle from an old car door lock pull rod to hook the spring through and pull.
Viewed: 326 times.
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| 01107 Springpuller connection - So, with the springs in the tubes and the puller connected its just a case of pulling through to the baseplate. You need a strong arm though and preferably a friend as the long stem in particular is a tough one to pull through- Boy those springs are strong! Don't be tempted to shorten the tubes- its designed to stop the mirrors flapping at highspeed. Naz warned me not to cut down the tube as he did just that on his first car and the mirror started to move at high speed.
Viewed: 321 times.
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01103 Mirror Showing temporary vivet fixing- Use 2 large rivets to hold the mirror springs in place.... then remove the springpuller tool. Eh voila!
Viewed: 300 times.
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| 01102 Building up Mirror stem- Here you can see work on build up of 1 stem in particular to accomodate the slightly different fit of the baseplate. Without this, to fit the baseplte would have meant dremelling so much off the mirror hollow that it would break through to the exterior
Viewed: 326 times.
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| 01105 Mirror Stem buildup - Here you can see the temporary gaskets and buildup on the lower mirror stem in particular. To get the fit right, once I hollowed out the stem I found that this lower edge was entirely made of the new material, so I actually highetened this stem side by about 3mm. I've got to say it was a right pain in the ass and took bloody ages but I know it looks right now.
Viewed: 302 times.
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| 01106 Mirror Stem buildup detail- Another shot showing the stems buildup.
Viewed: 323 times.
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| 01113 Mirror Before and after- Once all the stems were complete I could prime the mirror at last. Here is the before and after to show just how much work it took.
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