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D2 - Body and Exterior Bumpers, bonnets, glass, trims - Everything outside

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  #21  
Old 27th September 2017, 03:55 PM
MikkiJayne MikkiJayne is offline
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What he said ^

I'll measure an M6 rivnut in a bit. 9mm is probably about right.
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  #22  
Old 27th September 2017, 04:33 PM
HPsauce HPsauce is offline
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Good idea, but I don't have any, or the tools, but I worked out a slightly better bodge.

Popped to the local DIY shop and acquired some M6*25 bolts and nuts (only need 1 bolt!).
Inserted a bolt up through the hole from below and attached a nut from above. Checked location, length, ability to fit trim and then tightened the nut really hard to make a captive bolt.

Another nut and then a big washer and one more nut and we had a "platform" suitable to support my existing trim (after a bit of levelling/tidying on the underside).
Finished off with reusing the grotty washer from the original bodge (happened to be the right size) and final nut. Not elegant but it holds and can fairly easily be undone.
Could do with a cover for that recess though......
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #23  
Old 27th September 2017, 04:38 PM
HPsauce HPsauce is offline
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And, as is often the case, having bought some parts I never used them, ended up reusing what I had, which also saved on transplanting all the heated washer jets, piping and wiring.

I did remember, as advised earlier, to use copper grease on the wiper arm splines, though they came off fairly easily.

The final result is a tight fit all the way along the base of the windscreen, now including the central section shown here:
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__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!

Last edited by HPsauce; 27th September 2017 at 04:54 PM.
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  #24  
Old 27th September 2017, 05:17 PM
MikkiJayne MikkiJayne is offline
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I'll stick a rivnut in there when it comes over in the spring then
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  #25  
Old 27th September 2017, 05:22 PM
HPsauce HPsauce is offline
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It will need more than that if you do, the trim is missing the "pillar" that would allow a bolt to go through to the rivnut. So it will be a different bodge or replace the trim.
Luckily I have a spare one....... (though it has a bit of minor damage at one end that I need to sort out)
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!
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  #26  
Old 27th September 2017, 05:34 PM
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Dezzy Dezzy is offline
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You wanna job fixing tractors HP's
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  #27  
Old 27th September 2017, 05:59 PM
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notorious notorious is offline
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Great stuff

Next time change wiper arms and wipers to genuine new.
Then only change rubbers every year. They are available to order via TPS.
They are made in Germany by company called SWF which is premium German brand
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  #28  
Old 27th September 2017, 06:02 PM
HPsauce HPsauce is offline
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I've got the original arms for "show" but prefer the "aero" type for everyday use. They're also slightly longer giving better coverage (26"/24" vs 24"/23").
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!

Last edited by HPsauce; 28th September 2017 at 10:11 AM.
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  #29  
Old 27th September 2017, 10:25 PM
HPsauce HPsauce is offline
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A further intriguing little twist on the body lugs below the windscreen and the slots they slip into on the plastic trim.
The bodywork on my S8 has two metal lugs, about 10cm outboard of the washer jet locations, this is the offside one.



Both the trim on my car and the one I bought from our sponsors have the same part number 4D2 905 097. Yet the purchased one has THREE slots and it looks as if the fourth slot has been cut off, it has a manufacturing date of 12/94 and came with unheated washer jets in situ. The extra slots are equally inboard of the washer jets so I guess some cars may have had lugs there.

I felt along the bodywork and there was no indication that my car had ever had the inner pair of lugs, maybe it was a PF thing and they were later dispensed with as superfluous?
The slots are a plastic piece that is added on later, fitting over plastic projections and heat-welded in place, I think mine only ever had two..
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!) Oh, and a brand new engine at just under 30,000 miles on the factory one!
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
And before that a lot of Rover 800s, a few oddities, a lovely Triumph Dolomite 1850HL with Overdrive and way back in my schooldays an Austin Seven aka Mini 850!

Last edited by HPsauce; 27th September 2017 at 10:28 PM.
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