Boxer Clamshell Fit Question

almost always the first two...but of course the third is possible.

 

Another possibility, I suppose, is that there's so much frame rot in the front supporting structure that it has all started to sag. Newman's 19271 restoration was off by 8mm once the fiberglass was removed, thus leaving the front frame exposed and doing all of the "lifting" by itself.

 

Verify the triangular mount flanges on the 4 hinges all line up with the flanges on the clamshells. When the car is new, they all line up like they are laminated together. If the lid is ever removed where its retained with the nuts and bolts, simply match up those plates and the lid will be aligned. If they are lined up and the clamshells dont fit right then something has changed.

 

Both shells on the Boxer are able to flex a lot when one opens them by them selves from one side usually the drivers side since this is where the side of the car you will be standing to operate the releases.
Frequent openings will have the tendency to effect perfect alignment if done by one person on the same side as they will start picking up a flex created by that side only.
Also the placement of the air filters under the rear bonnet are under certain pressure against the rear bonnet when closed for proper fit.
It is not a good idea if needed to be opened often to keep them down with out being fully closed as this will effect their shape over time ever so slightly.
The remedy is to keep them always shut all the way after opening and alignment will always stay proper.
It is also a good idea to have two people when possible lifting on both sides when opening and let free fall shut when closing after lowering real close to shut.
Removing the hinges instead of unbolting the rear when removal is necessary for service will keep them always aligned.
I have seen lots of original cars on photos and in person in the eighties with out ever having any damage with minute imperfections at the rear left where all lift the rear when needed and is caused by flex.
When you evaluate a car you look at the paint to know if original and of course expect a fit as good as you will see in most photos printed when the cars were new.

Mario

 

You'll also find the build sequence number on those hinges (all 4) which should match the number stamped in the rear frame upper cross bar. The rest of the build numbers require some disassembly.

 

the clam shells usually fit very well, poor fitting clam shells are a sign of major collision damage.

 

I too believe the first 2. I've seen more that have imperfect fits than otherwise.