Both the windscreens and sidescreens arrive at the factory partly assembled, but there is a surprising amount of work to make them fit each individual car. Richard Marrick works in the ’brightwork’ area of the trim shop, where door handles, filler caps and other additional parts are fitted.
“It’s so much more than simply fitting the shiny bits though!” Richard laughs. “We have to alter most parts and we’re involved with building metalwork to fit in the rear of the car.”
When it comes to brightwork installation, it takes two chaps, one of whom was away when we visited so Gus Dickson from Research and Development had stepped in to help. Unwrapping the windscreen from its bubble wrap, the guys set about trimming the rubber on the bottom of the screen, and attaching the brackets either side.
“We put a bit of foam between all of the joints,” Richard explains. Between the bracket and the windscreen and between the sidescreen and the bracket are thick layers of foam to keep everything tight and to prevent wear.
Before the windscreen is positioned, Richard uses some grease on the rubber mounts, to prevent any squeaking and to allow the windscreen to move as it’s secured.
A greased washer and classic nut and bolt combo are used to fix the windscreen on. “This is sometimes quite tricky,” Richard states. “You’ll find most cars are similar, but some are a surprisingly different shape, and we have to alter how the screen sits to adapt to the slightly different curve.”
However, with Richard’s skill and experience he quickly figures it out and gets the windscreen fitting perfectly. Before tightening up properly, Richard works the rubber seal out from underneath and checks it’s all sitting as it should. After a final tighten, it’s all done.
The sidecreens are usually less difficult, but there are some tricks to getting them to fit well. The metal sheet – which is eventually covered with the same trim as the hood – is slightly bent for an inwards angle so it fits into the windscreen bracket. A quick visit to the vice is sufficient enough, with a slight push Richard uses his knowledge to know just how much to alter the metal.
“There are a few tricks you learn, the guy I’ve been learning from has been doing this for 40 years – I couldn’t have picked it up as quickly as I have without his tips,” Richard explains.
Making cars with natural materials makes things difficult when it comes to uniformity, but with the right workforce with adaptable skills and clever thinking, Morgan make every car fit together perfectly. Amazingly, this process only takes the two of them half an hour or so – Richard and Gus make it look easy!
Once the sidescreens are attached, the car is wheeled further into the trim shop where it gets the rest of the trim sorted, the interior tidied up and the plastic protectors removed from the sidescreens.