The Morgan Hood Stay - My Own Version.

The New Hood Stay Support 

This version of the Hood Stay Support was introduced by purchasing 1.2cm Aluminium Rod, cut to length and Drilled to suit the Wood Screw.

The Chrome Cap Cap and Threaded Washer sets were purchased on eBay

The full set of parts on my Kit.

The Aluminium Bar was purchased via eBay.

The Hood Stay is made from 2.5cm x 0.6cm bar cut 10.5cm long and cut to the tapered shape for design.

The Spigot is made from 2.5cm x 1cm bar cut 3.5cm in length.

All Bolts and Metal Washers are Stainless Steel.

Nylon Washers are of Polyester material. 

The diagrams were supplied by Designer colleague David Owens

Some Tools I used

Two Stays under construction

My Corner Shaping Rig.

For Detailed Cutting and Shaping

The Drill Set & Countersink Tool

Centre Punching the Drilling Positions

I started on the wrong foot by purchasing 2.5cm bar instead of 2cm so I set out to cut the width down while deciding to form a taper.

I preferred the finish so continued to use this wider bar.

Preparing the Spigot piece first.

I marked off the end of the short length of 1mm thick bar, donated to me by David, as per the drawing and drilled 2mm pilot holes after spot punching the locations.

I formed these Vice Jaw Protectors out of Perforated Aluminium Sheet which was all I possessed. 

While an odd choice, they did protect the surfaces 

After cutting to the lines using my small hacksaw and filing and smoothing with emery cloth this was the result.

At this point I realised that the nose of my piece was larger that in David's photo but decided to progress.

I marked the position for the fixing hole, centering on the 2.5cm square part of the spigot.

Next I spot marked the position with my spot punch.

The photo record here jumps a lot as here I have drilled a 6mm hole in the Spigot which I have not countersunk,

I realised that using the existing bolt type would not require one for me. 

I next filed the rounds on the top corners and smoothed the whole surface using emery cloth.

Working from a center line I marked out the recess in the Support Arm using the Spigot as a template for the recess. 

I then marked and drilled 4 x 1.5mm pilot holes along the base of the recess with difficulty controlling their verticality. 

These allowed me to break out the infill once the two sides had been cut.

It was then a case of file fitting the two parts so that they meshed together well.

I then center marked and drilled another 6mm hole in the base of the support arm. I used the sides of my small grindstone set in my hand drill to round the lower corners 

I used a series of drill heads to countersink the hole to fit the screw head of the longer 2.5cm x 6mm Stainless Steel Bolt (sent to me along with the Nylon Washers by David)

A final rub over with emery and I was ready to Trial Fit the parts.

At this point all is well. The 2cm Spigot Fixing Bolt needed to be exchanged for a 2.5cm Bolt that I had in stock.

The alignment between Stay and Spigot appears to be good.

Unfortunately, not having a pillar drill to keep the pilot drill holes vertical has left me with a small groove in the side of the prop recess.

I failed to purchase a small piece of Aluminium sheet with which to fabricate the prop support in David's design. 

However, I utilised this tapered part of an old aluminum door knob and replaced this with the Aluminium Rod purchased for the next set made.. 

The converted door knob.

The support fitted to the inner wall. The Chrome Cap was introduced following this plain version.

The prop in its supported location.

It was then just a case of refitting the prop with the recommended Thread Lock.

Thread Lock will prevent loosening of its fixing bolt during frequent use.

Best Wishes

Frank

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