Morning all.

I'm a first time buggy builder and learning a lot so far.

I am presently repairing the spine and measuring up for fitting FOC floor pans. The chassis came to me shortened already, but I'm happy it is square and true.

I sat the body on to check how it fits and give an idea of where the pans should be and where to trim them.

The body is likely 50 years old and will need attention.

The photos show how the body is sitting high on the rear outriggers and doesn't fit the Napoleons hat well at the outside corner.

Is this usual for a body?  Or is it the passage of time having an effect?

What is the best solution for making the body fit better?

Can bodies be "spread" to widen/lengthen or is it a cut & widen & reinforce job?

Thanks Matt

Do the 4 mounting bolt holes at the end of the Napoleons hat get used to mount the body?  I haven't seen many buggies use those, and mine don't align really.

Some largish gaps

Probably not the best one to advise on this, but yes, the Bodyshells can change shape quite dramatically over time, and with a bit of heat and gentle persuasion, can be reshaped. I managed to raise a drooping front wing over a week using a fan heater and a trolley jack underneath it, and I know others have changed widths using ratchet straps a few clicks each day.  I think you are also missing the large rubber seal that takes up much of the gap between where the body touches the pans.

I'm sure someone will be along shortly with some better help though 

That's probably one of the best fitting bodies that I've seen. Just use a thick-ish gasket, something like neoprene, build it up double if need be. If you've got a gap down the sides use longer bolts and snug them down gradually over a few days.

Bodies are generally held by just the bolts down the sides of the floorpan and a few in the rear cross members, I use M8 x 30mm stainless button head screws with penny washers up top, standard VW channel washers, flat washers and nyloc nuts underneath. Don't worry about the front corners.

That's probably one of the best fitting bodies that I've seen.

 Don't worry about the front corners.

Wow. I want expecting that. Shows you what I know!  And what I have to learn.

I'm possibly overthinking.

As I have access to the inside of the napoleons hat. I was considering putting some captive nuts in there to enable the front bulkhead to be bolted down.  Thoughts?

Matt

I'm possibly overthinking.

 
We have all been there   

That's probably one of the best fitting bodies that I've seen.

 Don't worry about the front corners.

Wow. I want expecting that. Shows you what I know!  And what I have to learn.

I'm possibly overthinking.

As I have access to the inside of the napoleons hat. I was considering putting some captive nuts in there to enable the front bulkhead to be bolted down.  Thoughts?

Matt

Whatever works, there are no rules.

Those are good gaps and will get smaller as the body sides are tightened down, it is worth putting some box section around inside the floor pan lip then riv nuts can be fitted in the top so the pan the gasket and body pull down as some new pans are so thin they just flex to the body shape.

From Meyers Manx instructions...

Looks a wise move. 

I've spent some time measuring the body across the front and rear bulkheads and comparing to the chassis.

I've decide the rear bulkhead needs to spread by 10mm either side

So it's presently sat with a 20kg weight on the parcel shelf.

This body has been sat loose for many years.