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Making support cheeks

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Make support cheeks -B- with basic material Multiplex plate 600 x 120 mm, 25 mm thick.

Fig 1: Identifying Support Cheeks Dimensions
G03155186Courtesy of PORSCHE OF NORTH AMERICA, INC.

A4 = Straight pin 6 M6 x 40 / B = Support cheek

  1. Work procedure:
    1. Transfer 160 mm radius to the multiplex plates.
    2. Saw multiplex plates along the traced radius. The foot of the sabre saw must be tilted by 15° for this purpose.
    3. Drill four 6 mm holes in the support radii of each support cheek to provide clearance for the Tucker bolts on the hardtop body. Obtain the dimensions from the hardtop body.
    4. Drill three holes, 20 mm deep, 6 mm, per support to cheek to secure the support cheeks -B-  to the base plate -D-  with the straight pins -A4-  6 m6 x 40 from the set of fittings - attach support cheeks -B-  . See Fig 1 .