Converting a Series 1.5 Bonnet to Covered Headlamps

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Step 1 is to fit up our patterns taken from an original Series 1 bonnet. These are “flexible shape patterns” that are usually used for wheeling up or shaping panels. Here, we carefully lay them over the panels to mark out the position of the covered headlamp flanges. These are cut to mark the panels exactly 1/4″ BACK from the flange location. The factory holes in a typical Series 1.5 bonnet are ALL OVER the place – I think that they may have continued to use the Series 1 stamps and just cut the flanges out by hand – seriously.

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