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Boot Lid Hinge Springs
The boot lid hinge springs on an E-Type roadster are a really strange set up. They consist of multiple thin pieces of spring steel approximately an inch wide and rolled into a short tube. These are purchased one at a time and must be loaded onto the hinge to finally get a spring to lift the hinge to the open position. Loading them is a finger mashing, finger cutting, curse-a-thon. This is what I did.
The hinge and it's broken spring look like this.
The spring should hook over the bolt to the left and, when the hinge is in the closed position, be bent backward over the curved part to which it is anchored.
These individual leaves are attached to the curved shoulder via a small bolt which can be just barely be seen at the bottom of the shoulder.
I read several write ups about how to load these leaves onto a hinge. What follows is the procedure that I came up with and is a mixture of what others have done and what I worked out as I went along.
It takes five leaves to make up a spring for one hinge. Some folks feel that six work better but I stuck with five as in the original.
I started with a pin punch clamped in a vice. I then forced the first leaf onto the punch, using a screwdriver to spread it, such that the end of the punch came up just short of the hole.
Then I rotated the leaf 90 degrees and forced it onto the punch.
The next leaf was done the same way.
Next came the chore of "nesting" the second leaf around the first. I used a 1/2" extension slipped into the leaf and pulled it out and down until it wrapped itself around the first.
This was repeated until all five leaves were nested to form a spring.
Now to figure out how to get them mounted on the little bolt that holds them all together. Just a word of caution; the leaves are sharp and hard and will damage your bolt if you try to force them onto it. Keeping the holes aligned will aid in this process. By the time I got enough clamps on this mess it looked like this. If you loose your grip on them such as to allow the holes to misalign you have to start all over again.
Once you get the spring off of the punch, insert the little bolt from the inside so that it looks like this. Yea, you can probably guess what that little streak of crimson is.
Now the spring is ready to be mounted to the hinge. Don't fully tighten the nut so it can be rotated over the anchor bolt.
I used a pry tool that was originally used to pry brake shoe return springs into place on drum brake systems. A large screwdriver might work as well.
And this is what the completed spring looks like. Don't forget to tighten the little bolt when you are finished. From what I can see when looking at the old spring they appear to have been painted as an assembly and that is what I will do.
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