| This is 
				what I purchased from eBay.  It's not in too bad 
				of shape, but needs polishing beyond my capability to make it 
				look new again.Also, another friend from the forum's, Bob Hunt was kind enough 
				to send me some spare slats that he did not use to help take 
				care of
 any of mine that had dents that would not straighten or were 
				scratched too deeply.  All in all, mine weren't too bad, 
				but I swapped a few out.
 
				 I did get 
				the attaching feet and the plastic clips that actually hold the 
				rack off the deck surface.I'll post pictures and a link of where to get some spare parts 
				for these as we assemble.
 
				 Thanks to a 
				great packaging job by Panda, the deck lid arrived with only one 
				broken support andminor damage to the corner.  That will be taken care of at 
				A&E very soon.  Thanks again Andy!!
 
				 This looks 
				pretty good, with no rust which is huge.  But if you look 
				dead center at the rear of the deck,you will see what happens when you have a gas filler cap 
				pointing the wrong way and you open a deck lid too far.
 
				 It's hard 
				to see, but there is a slight bend in there.  We will fit 
				the lid to the car before painting toinsure that if any straightening is called for, it will be done 
				prior to color and clear coating.
 
				 The bottom 
				was easily stripped and epoxy primed.  Nice and clean with 
				no rust makes it easy. 
				 The top has 
				been blasted, dents removed and we begin to place the rack for 
				drilling the mounting holes. 
				 After 
				talking to several owners with these platform racks, the 
				consensus was that the distance fromthe rear edge of the deck, to the back of the forward mounting 
				feet was 21 1/2".  This will allow for
 plenty of clearance over the gas filler cap and keeps all of the 
				holes hidden under the bottom reinforcements.
 
				 Side 
				placement dimensions are between 4.25" and 4.5" based on your 
				actual deck lid and rack.That's easy enough to measure and center once you have it all 
				together and placed front to back.
 
				 I am not a 
				fan of just using sheet metal screws to attach luggage and roof 
				racks of any type. There areseveral ways around this and I really liked the 10 X 24 Pop JackNuts.  
				These close up as drawn tight and provide
 a good backing that will securely fit the inside of the deck lid 
				and allow me to get new matching stainless screws.
 
				Deck lid is under epoxy prime 
				and waiting for the Pop JackNuts to arrive. 
				 
				Pilot holes on the left.
				 
				 
				And pilot holes on the right.
				 
				 Well the 
				Pop Jack Nuts came in the wrong size, so that option is gone.  
				More on the well nut that I'm using later. Today's 
				exercise was test fitting the deck lid.  It had some "gas 
				filler" damage and one side was higher than the other,but Jorge and Joe took care of that and made sure that 
				everything will line up perfectly before it's painted.
 Just for 
				reference, here's the proper paint line for the Kammback Satin 
				Black. 
				 
				Before anything else is done, 
				let's see just how straight this is. 
				 
				This picture's for BobbyD.  
				He loves my neatly organized trunk.  That's why I need a 
				luggage rack, for more room in here. 
				 
				Jorge is fussy and that is 
				fine with me. 
				 
				The black semi-circle at the 
				filler cap area will get some attention with the dolly, as it is still a 
				bit high.Once Jorge gets done with it, it will be be perfectly aligned 
				and matched to the rear panel.
 
				 
				This lid stayed at A&E and my 
				original is back on and the car is back under cover in the 
				garage. 
				  
				OPTION #1, WHICH IS MY 
                FAVORITE
 
				I got these from Fastenal 
                #0162808, 
                Au-ve-co # 13014.  These are a 10-24 machine thread and a width of .382" 
                which takes a .390 or 25/64's drill.  This provides a nice sealing lip against 
                both side of the metal and allows for the right size machine 
                screws.
 
				.JPG) 
				Well, after much debate, we 
                went back and forth and decided to go with the Pop Jack Nuts in 
                metal, but with a seal. 
				 
				 
				A little more detail about 
                these and how they work. 
				 
				The seals are #11 neoprene 
                seals that should work well under there. 
				 
				These are the two screw sizes 
                that you will need.  I like the one inch length myself. 
				 
				Note how the 10 X 24 Oval 
                Screw head fits down into the racks corner clamps. 
				.JPG) 
				THIS IS OPTION # 2 AND NOT MY 
                FAVORITE, BUT THESE HAVE BEEN AROUND CARS FOR YEARS 
				 
				This is what I will use for a 
                substitute.  These are for roof racks and do provide a good 
                seal as well. 
				 
				The thread stops 1/3 of the 
                way up and the rubber compresses and expands on the inner side 
                of the panel. 
				 
				This size accommodates a 
                #10-24 Stainless Screw that will fit the trunk rack hold down 
                clamp perfectly. 
				 
				Good amount of surface to 
                retain and to seal against the painted deck lid. 
				 
				  
				This is all sealed like the 
				hard top and will be ready for sanding today. 
				 
				The holes will be drilled 
				prior to the sanding and painting, then the jack nuts will be 
				installed. 
				 
				First two coats of color on 
				this side went on this morning. 
				 
				This is what the Pop JackNuts 
				look like when collapsed on themselves after being drawn up.This provides a good anchor for the luggage rack and with the 
				seals on top, they should never leak.
 
				 
				Those two stick up, the other 
				six are hidden. 
				 
				A close up of the front set 
				compressed and you can see the seal in the inside lip above the 
				threads. 
				 
				Back of the deck near the gas 
				filler. 
				 
				All four in place and the 
				paint goes on this side tomorrow. 
				 
				Well, we have color as of 
				yesterday. 
				 
				These guys will need tapped 
				out a bit, but that's minor. 
				 
				One of the old support 
				gaskets in place. 
				 
				This is actually what holds 
				the rack support bars in place, not the metal clamp on the end. 
				 
				This guy here is just a 
				cover.  You can see down through the left side.  The 
				other is hidden in the cross brace. 
				 
				The paint finish is great 
				without being sanded or buffed yet. 
				 
				That leg sticking up in there 
				supports the bars.  Next week, sand and buff the clear 
				coat. 
				Now I need 
				Nu-Chrome to get 
				the rack finished.  I do have all new attaching parts.  
				More on that later. 
				 
				Today the parts were ready so 
                I picked them up. 
				 
				First the slats, which were a 
				bit twisted and very dull. 
				 
				These slats looked terrible 
				prior to being polished. 
				 
				A pretty nice job on these, 
				considering what they looked like going in. 
				 
				Stanchions and screws for 
				slats, but a few are missing. 
				 
				They did a great job with the plating and 
				polishing. 
				The two larger bars at the 
				rear hold the slats and the front bar is at the rear of the rack 
				to provide support and a back stop. 
				 
				Replacement screws to be 
				polished to fill in for the missing ones above. 
				 
				One of my spare racks used 
				for reference.  I've got to start cleaning parts out of my 
				basement. 
				 EDIT: 
                1/9/13 The 
                mounting parts below that I was lucky enough to get out of 
                Atlanta are no longer available.   If I hear 
                of a source for these, I will post it as soon as possible. 
				
				 
				The plastic parts go in the 
				end of each slat and the pins are in the end of each tubular 
				rod.  These pinsrest on the plastic stand offs and hold the rack of the deck lid 
				and allow the (4) chrome end caps to lock them down.
 
				
				 
				Allan painted the black on 
				the deck lid after it was installed to be sure that it was 
				matched on both sides. 
				 
				Even gaps all around the 
				sides and rear.  Deck height matches rear panel perfectly 
				too. 
				 
				Allan and his guys did a 
				great job with the paint and making sure the deck lid was square 
				and would align perfectly. 
				 
				Picked up the rest of the 
                parts to 
				complete the job.  All of the screws are polished and ready 
				to go. 
				 
				The etched number is my job 
				number from plater.  
				It's how they keep track of the thousands of parts in process 
				there. 
				 
				This is how they fit into the 
				ends. 
				 
				I use this cleaner on my 
				kitchen appliances and it works great. 
				 
				All of the plastic end caps 
				are in and ready to go. 
				 
				It's best to leave all of the 
				screws about one turn from tight to allow a little twisting when 
				you install the rear bar. 
				 
				And for the final installation..... 
				 
				It definitely adds some bling 
				to the back end of the car...... 
				 
				I'm glad that we went with 
				the Pop JackNuts.  Installing the screws to a threaded 
				insert was a lot betterthan going with the self tapping wax cover screws into the top 
				of the lid.  These feel very secure and tight.
 
				 
				That's it, already for summer 
				cruising. 
				 
 And as 
				always, another fine paint job completed by Allan and his guys at: A&E Auto 
				Body 50 Alden 
				Street Pawtucket, 
				RI  02861 
				401-722-2204    |