TD6 '02 FFRR Sidelight Repairs (Fixings) |
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1 - Missing flange broken off by a previous owner (not me this time :)) – 53 viewsThis causes a loose fit of the sidelight cluster so a repair was required to keep everything holding together
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5 - Old bolt spinning in its fixing – 47 viewsThis is a poor piece of design. I think the bolt is supposed to be held in place in a press fitting, but when this goes the bolt will just turn making it difficult to undo the plastic nut and remove the sidelight. So to replace the bolt!
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2 - DIY Flange fitted – 55 viewsI had an old kitchen bin lid lying around, so cut out a piece to fit. Drilled holes in the right places and drilled pilot holes into the sidelight housing. Don't go too deep here otherwise you are through to the other side.
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3 - DIY Flange fitted (note hole 1/3 of the way down) – 47 viewsI trial fitted and marked and then drilled a hole in the new flange. This was to post fit a grub screw to act as the "lock"
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6 - New Bolt with lock nut in place – 53 viewsYou need an M5 x 50mm, a 60mm might be better, as I found one of my plastic nuts had lost its thread for the first centimetre or so. Halfords do these bolts (an nuts to go with it) in a pack HFX511.
I tightened the nut up to the bolt (not too tight or you may break the fixing) enough to hold and ensure it doesn't turn.
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7 - Plastic Wheel had stripped its thread so needed spacing – 57 viewsOne of the plastic wheels had striped its thread so would not hold in place. Some trial and error fitting was required to discover the required amount of spacing needed to get a solid fit. in the end I needed another nut and a 2mm washer.
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4 - New flange locked in place with grub screw – 52 viewsHere is the sidelight in place, and after fitting the grub screw to make the lock on the flange. If I could have found the right sized screw this could stay in place and work as the original flange. The one I used is a bit too big and will have to come out if I remove the sidelight housing again.
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8 - New bolt, wheel and nut in place – 53 viewsEverything all tightened up and together again
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9 - howto – 47 views
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