Now in 2010 we do not  have a JBA Factory producing any vehicle that has been evaluated in any articles in the various Kit Car Press magazines or approved by VOSA BIVA testing.

Please note these are the old build pages from 1999 to 2004 when we had a JBA Factory in full production from 1982 that was regularly featured in the Kit Car Press and complied with regulations including passing UK Vosa SVA/BIVA tests and TUV tests in the EU.
A 2004 JBA Engineering Ltd Sports SR kit has passed the new BIVA test in June 2009.

Spanner Sizes
Spanner Sizes fits on the head of a bolt. 8mm spanner fits M5 bolt, 10mm......M6, 13mm......M8, 17mm......M10. 

Options
Various Interior Styles
Side Windows

What You Will Need 
Anti-Burst Door Locks. 
Exterior Door Locks.
Interior Door Locks.
Interior Grab Handles.
Door Check Straps and Pins.

Have a look at some of the interior styles on other JBA Falcons. This is the time to copy any that you like. If you can speak with the owner. You can modify the doors at this stage. In the photo below Derek Bintcliffe has fibreglassed in arm rests and done his own design on the doors.

Follow the instructions and measurements in the build manual. 

Have the door seal in place before starting this task. Use the door seal as a guide removing and refitting the door to get things right. The door must compress the seal. The reason for this is if you don't. When you come to fit the seal later the doors will not close. Which means re-siting the door hinges and drilling new holes.

Do not cut the seal to fit the door size. This seal goes all the way round the car from the N/Side upright round the door and up the windscreen frame along the top and down round the other door and stops at the Off/Side upright. Just drape the rest over the car.

In the photo above Doug has fitted the interior door support brackets.

I trimmed the door flanges as per manual using a small angle grinder, which I did outside, as the dust gets everywhere. Some other builders have added wind up windows and even electric windows. 
Next was to cut away part of the door flange top and bottom to allow the door hinge pins to clear. This is simple follow the instructions in the manual.

Kenny fitted the hinges and the hinge support plates supplied by JBA.  I used different door hinges which were pre-drilled, these are available from Europa.

Where the hinge fits on to the door you need a spacer to achieve equal shut lines. We did this by using washers between the  hinge and the door. Top and bottom. Sometimes with more washers in the top bolt or vise versa.

As with any door hanging  it is all trial and error stuff in order to get the same shut lines all round. It does take time. Once this is done with washers we measured the space between the door and the hinge and  made up a metal spacer to fit the space.

New strength bracket supplied in kit shown in Doug's photo above.

Door Locks

Follow the manual. Kenny fitted the Anti-burst door locks on the edge of the doors using the template supplied with the manual. Make sure that the Anti- Burst locks are set to their first position, in order to fit the door striker plate onto the CBU. Now fit the new strength bracket.
We fitted the exterior chrome door handles available from JBA.  These door handles were standard fitment on the Cortina mark 3 and Capri's. The handles JBA supply now are Jaguar door handles. 
Modifying the connecting rods from the donor car. This is a right fiddly job you need tiny fingers. (coupling up the connecting rods I mean)

Doug's strengthening brackets were made up and fitted to the interior  of the doors to hold the interior door handles. These are chrome handles from a Jaguar. They also come in black from ERF lorries.

Strength Brackets

Other strengthening  brackets we fitted, were for the door hinge support brackets to the scuttle loop just visible at the gear lever and from the windscreen frame to the scuttle loop and for the door check straps.

The photo above shows the heavy insulation material fitted to the inside of the door, this is to help add weight to a light door. Doug has added the door check strap between the door and a plate bolted to the scuttle loop. Position this carefully as too low and the strap will rub on your leg.

Fit the door grab handles in a suitable place.

Door Problems 
Sometimes the doors may show a slight distortion.
My nearside front door had one at the top near to where it meets the scuttle. I cured this by turning on an electric fan heater, pointed close enough to the door without damaging it. Once the door was warm I clamped the door to a solid part inside the CBU and drew the top front of the door in a tiny wee bit, not the full distance required and left it overnight after switching the heater off. Over the next two days, I repeated the process drawing in the door a wee bit each time, until the door was fitting fine with the clamp removed.

 
The door handles must be SVA approved. The driver must be able to reach and open the passenger door from the drivers seat.

The next page deals with fitting the side screens and windscreen to the CBU (Central Body Unit) 

   Photos Courtesy Of Doug Philp.

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