Windscreen wipers

Wiper spindles

I had been pre-warned by Meena from GD that the central bundy tube may be too short, as their supplier had sent a batch of wiper assemblies and some of the bundy tubes had been found to be the wrong length. Mine was part of that batch. The spindle to spindle measurement on my car was 505 mm, which was 35 mm longer than the bundy tube provided. So GD arranged to send me a longer bundy tube with pre-flared ends.

After getting the new tube and before I attempted to drill the holes, I again checked that the bundy tube was bent to the same curve as the scuttle. The wiper mechanism was again assembled on the bench and the spindle distances checked against those marked on the scuttle. This time they only needed a millimeter adding to the markings.

Wiper mechanism bench fitted. Note: the motor is facing the wrong way

The outer edge of the rubber washers were then marked at 5 mm from the screen rubber and the eliptical spindle holes were marked on to masking tape using the inside of the washers. The centres of the holes were established and marked.

Offside spindle markings

The metal ferrule was used as a guide to drill the hole at the correct angle to the scuttle.

Drilling the holes

The holes were drilled under size initially, then gradually opened up with a hand file.

File used to open up holes

The spindle ferrules had to be ground down to get the same angle as the chrome ferrules and to expose a little of the spindle thread. The spindle mechanisms and long bundy tube were offered up from under the scuttle and the rubber washer, chrome ferrule and nuts fitted to the outside.

Trial fit of spindle

Both spindles finally in place

Wiper motor

Once I was happy with the spindles, the wiper motor was fitted to the cross brace using the U bracket/strap, with the rubber mount below it. At this point I realised that the piece of bundy tube that connects the motor to the nearside spindle was also too short by 10 mm.

Bundy tube to motor short

Luckily I had the short central tube that GD had replaced, so I made a longer tube to connect the motor to the spindle! I cut the tube 2 mm longer than required, then flared the end with a brake pipe tool, before fitting (not as easy as it sounds as the bundy tube is not soft copper). The electrical connector on the loom was then pushed in place and held by a long tie wrap (not shown in photo).

A new section of bundy in place and motor fixed in place

Finally the connection to the motor, the mounting bolts, spindle nuts and the chrome spacers were fully tightened. The park position of the motor will need to be checked once the power can be applied - the wipers park on the opposite side to usual.

A job I had been dreading was done.