Fitting Bonnet Catches (Aero Catches)

Well I have now amassed a number of parts including the suspension package. There are a few more parts which are still required but these will have to wait to next pay day.

I have a couple of small jobs which I can tackle now one of which is my newly acquired bonnet catches.

I have opted for catches opposed to the cable operated cabin handle as it will save me having to refit the old handle when it comes to swapping the bulkhead and avoiding the clash between old and new, instead now I can remove completely. Plus it looks pretty neat.

Out of all the bonnet pins available I chose the Aero Catches as they give you the ability to lock the bonnet and they are flushed fitted which I prefer.

 

The first problem I found was find a suitable position to mount them, due to the defenders bonnet shape, catch size, hole position and wing position there was no place I could mount them. So I made a bracket to support the pins which was mounted of the radiator supports. 

With the steel section cut to the correct size it was time to remove the existing bonnet catch and spring.

I then fixed into place the steel support bar with 2 rivets.

 

Once this had been complete it was time to start measuring to determine where the pins would come through the bonnet, this tool a while! eventually I thought I had worked it out, and drilled my first hole in the bonnet. I then closed the bonnet and marked the hole position on to the new steel bar. 2 hole where then drilled into the steel to take the bonnet pints. The pins were installed, bonnet shut to see if the holes where in the correct place. They where out by a few mm. So I used the template and centered it onto the pins and marked the hole which was required in the bonnet for catch fitment.

Then it was time to try out my new nibbler, great tool, however it did struggle to get the tight turn at the bottom of the catch. I then filed the holes to remove the tight spots and finished where the nibbler couldn't reach.

I then fitted the catches into the holes, drilled the holes for the bolts and then bolted them both into place. Quick test to ensure the pins fitted and after a quick location shuffle the hard bit was done. The only issue with the pins is caused by the angle of the defenders bonnet I.a. it slopes down to the nose of the car and as a result so does the catches. This means that when the pins enter the catches the rub slightly as the pins are straight. Had I put more thought into I could have angled the pins. However they work fine as they are so that's how they'll remain.

Next I removed the support bar and painted it to stop it rusting up.

Once painted it was then re-fixed but with 4 rivets this time, the pins were leveled up and the rubber bumpers added.

Job done, and I think it looks good. But it will look better when the defender isn't beige!