Jaguar XK120, XK140 Roadster/OTS

Jaguar XK120, XK140 Roadster Convertible Top Installation Instructions
For Product #s: 120-3412, 120-3413 & 140-3414

To Order this product by Phone, Call (805) 921-0100 or (800) 222-9577, Monday to Friday, 8 am to 5 pm PST

The following information is supplied as a customer service guide only. World Upholstery & Trim recommends professional installation of all our products. No guarantees are granted with regards to the use of this guide.

Tools required:

• Slotted Screwdriver
• Scissors
• Marking Pencil or Chalk
• Metric Socket Set
• Hammer
• Awl
• Spray Adhesive, 1 lb. (#9410)
• or Brush Adhesive, 1 Quart (#9411)
• Weatherseal Adhesive, Black (#9412)
• Protective Blankets
• Masking Tape
• Pliers or Vice Grips

Additional parts not included that may be required:

• Pair of Top Straps (#120-3507)
• Top to Windshield Weatherseal (#120-3506)
• Front Wood Bows, Pair (#120-3281)

General Preparations:

1. Inspect contents of box against your invoice, especially color and material.
2. Protect car with fender covers or blankets to avoid damage to finish.
3. Tape protection over inside and outside of plastic window if so supplied

Pre-Installation Preparations:

1. Delay installation if all parts necessary are not at hand.
2. Before beginning installation, inspect top frame for loose fasteners or bent bows, lubricate all moing joints.
3. If wooden header bows are to be replaced, remove top frame from car noting position of special washers at mounting point, remove top to windshield seal #16 and wood screws below it, new wooden bows should be covered in cotton headliner fabric to match underside of top.
4. If straps are to be replaced, (it is not necessary to remove the top frame) remove the tacks (#12) on the wooden header bow, all the screws, washers & dome nuts (#7) on the center bow (#8) as well as all the split rivets (#15) on the rear.
5. Top frames were originally a light grey/green color, if you removed the frame, now is a good time to repaint if necessary.

Convertible Top Cross-Section

Top Removal:

1. Raise the top and latch into position.
2. Gently pry front pin beading #10 from wooden header bows.
3. Remove tacks or staples securing the water shield (#9) and the top fabric (#1) to the header bows.
4. Remove the 2 screws (#14), along with finishing washers and dome nuts, located on the rear.
5. Remove top fabric from the car complete with rear bar.
6. Remove rear bar from top fabric, noting its orientation.

Top Installation:

1. With new top fabric on a clean bench or table, center and using contact adhesive, glue rear bar to flap sewn on lower inside edgeof top. Trim flap so as to have enough material to tuck in on back edge.
2. If using the original chrome framed window found on later style long tops, center and install in blank curtain.
3. Mark center line front and rear.
4. Install header rubber seal (#16) using weatherstrip adhesive.
5. If the frame has been removed, re-install and latch top metal header bow (#3) to windshield frame (#6). Make sure the top to windshield rubber seal (#16) is in place.
6. Drape the top fabric over the frame.
7. Engage rear bar in chrome top hooks on tonneau panel and draw the fabric forward over the frame.
8. Locate and center top seam over rear bar (#13) and re-install the 2 screws, washers and dome nuts (#14) and tighten. Make sure fabric is pulled taut from side to side but not tight.
9. If the straps are being replaced, fold the rear end under and, using 6 brass split rivets (#15), attach it to the rear bow (#13).
10. Draw the straps forward to the header bow (#2) and pin it with 1/2" tacks (#11). Make sure the straps are taut not tight. Replace all the oval headed screws, finish washers and dome nuts (#7) found in the center bow (#8) and tighten.
11. Draw the top fabric forward, taut and center, over the header bows. Begin at the center tack or staple all the way to the header bow. Make sure the staples or tacks are in a line that will be covered by the pin beading (#10) later. Keeping the fabric taut, continue tacking out to the ends.
12. Tack or staple the water shield (#9) to the header. The bound edge should barely be just touching the glass.
13. Seal staples with silicone sealant or similar.
14. Re-install the pin beading (#10) using a soft mallet. To simplify installation, mark and drill a small pilot hole for each of the nails in the pin beading. If pin beading is not available, use hidum and chrome ends provided to cover staples or tacks.
15. Install the side screens.
16. Pull the rear sail panels down to align with the side screens. Mark the location. Then install the 2 or 3 fasteners per side that attach the fabric to the body.
17. Unzip the rear curtain, fold the curtain in and up to the lift the dot fasteners on center bow (#7). Mark and install the female fasteners. Special Note: Early cars did not have the zipped up curtain (image below) and do not require this step.
18. Remove tools and protective coverings.
19. Check for excess adhesive and clean off with solvent.