Scuttle part 1

So new year, new challenge....thought it was time to have a look at how the scuttle comes together and fits to the chassis.

Approached this stage of the build with some trepidation as the scuttle along with the rear panel requires some panel bending, so quite a sizeable task awaits the amateur builder - definitely out of the comfort zone with this task.

Spent alot of time reading other builder blogs, general web research, studying photos in order to establish the stages to work through in achieving a fully built scuttle. What I established early on is that:

• You need a jig / platform to assist with the initial bends
• You need to ensure all the tabs on the fire wall are folded out forwards and most importantly are flat along the edge which the top of the scuttle will form its shape over
• You need alot of patience and perseverance, plus three pairs of hands! 

So first task, get the folds in the firewall tabs done, I needed a straight edge to act as the guide for the bends and to ensure they folded flat in relation to the edge of the firewall - a steel rule assisted in that together with a "toffee" hammer to tap the fold as flat as possible against the straight edge - overall pleased with that stage. take breath, onto the next stage.

I built a temporary jig/platform and attached the fire wall to it. I then took the top skin of the scuttle and flexed some bend into the panel to at least assist with the bend over the top of the firewall.

The principle is actually quite straightforward albeit you don't have enough pairs of hands, the steel has a mind of its own and its initially very flimsy whilst the first few tabs are secured. Basically, the tabs on the firewall are to be lined up with the tabs on the front of the scuttle skin, rivet together which provides an initial fix and working out form the centre repeat this process along the flat-ish firewall top edge.

Its important to work centre out evenly - centre, left tab, right tab, left tab, right tab etc each time push the scuttle down onto the top of the firewall, locate the two tabs together and cleco / rivet in place

I left the side tabs free at this stage as to be honest although the jig helped with the initial fixings, the side fixings were more challenging and I felt I needed the chassis to now become the jig and help pull the sides of the skin round.


In essence, the scuttle top skin needs to bend round the firewall edge but at the same time also pull the sides of the skin in as well - the jig I built was not allowing for that, so next best thing has to be the car chassis.

6 x M8 rivnuts were fitted along the side panel tops and a further 3 x M6 rivnuts along the edge of the firewall, battery tray panel area. these allow the scuttle/firewall to be screwed into position with dome head screws.

I offered up the part built scuttle, firstly screwed in the firewall into the chassis frame and once that was secure bent the scuttle skin over the remainder of the firewall on either side and pulled round locating into the M8 rivnuts secured with a dome head screws.

this proved surprisingly rigid and forms the initial shape quite nicely.

Some trimming of the panel is still needed to get a perfect fit in the corners and I note the top edge of the firewall as it bends down on the drivers side is pushing backwards slightly so I need to ease that forwards as I pull the skin over to meet with the M8 rivnuts/screws - I think this should be easily resolved.

Overall pleased and encouraged with how this has gone.

So part one done - a scuttle has been formed into the shape, next stages are to:

• Fine tune fitment around the pinch areas I have noted above
• Get a nice thick bead of Polyurethane sealant going across the back of the firewall / inside scuttle area
• Blind Rivet / Poly seal the dashboard bracket to the cockpit side of the scuttle (this should pull the true shape in nicely)
• Cut off and trim the front temporary tabs